Inside Mining January 2017 by 3S Media

www.miningne.ws

a f r ic a n u p dat e s o n t h e

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

Hot seat Thierry Pimi, new managing director of Cummins Southern Africa

bme

Adding more value to explosive technology

Welgemeend Colliery Fine-tuned for coal

Award-winning plans Sasol's success stories

mine compliance World-class labs

ISSN 1999-8872 • R50.00 (incl. VAT) • Vol. 10 • No. 01 • January 2017

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contents

afr ic an up dates on the g round a nd

u nde rground

Editor’s Comment 5 Burning bright

Chamber of Mines

Cover Story 6 BME

LeGISLATION

Adding more value to explosive technology

New Mining Charter draft concerns

Successfully navigating BBBEE codes

Mechanised Machinery

Africa Round-up 8 News from around the continent

40 Necsa Every mine’s bedrock for sustainability

New MD focuses on customers

Fossil Fuel Foundation 11 From heydays to low days

Economics, Finance & Risk 12 Coal’s powerful role

44 Largest hauler launched in

January

Southern Africa

Education & Training 46

2017

Preventing plastic welding errors

Latest Equipment & Technology

Stacking equipment for stockyards

Reducing risk with leading tech

Adhering to market requirements

Quality and design for better safety

ON THE COVER p6

Charting a water-secure future Prolonging the life of cyclones

Coal Mining 24 An output exceeding expectations 26

Tips for top lab results

Transport

Coal Processing 14 Stockyard principles

The RTEX reduces energy consumption by 50%, is 25% lighter and is more compact than traditional breakers

Improving underground safety

Laboratory Analysis

Hot Seat 10 Cummins SA Distribution Business

New handheld pneumatic breaker

www.miningne.ws

Market News 52 The latest news from the

Award-winning plans

A F R IC A N U P DATE S O N T H E

African mining industry

Mining in Africa 29 Gearing towards full production

G RO U N D A N D U N D E RG RO U N D

HOT SEAT Thierry Pimi, new managing director of Cummins Southern Africa

BME

Adding more value to explosive technology

Mining Indaba 55 Good advice and quality data

Maniema Gold acquisition in progress

Events

New scrubber for Debmarine

56 R educed rates for Mining Indaba WELGEMEEND COLLIERY Fine-tuned for coal

AWARD-WINNING PLANS

Sasol's success stories

MINE COMPLIANCE World-class labs

ISSN 1999-8872 • R50.00 (incl. VAT) • Vol. 10 • No. 01 • January 2017

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

BME’s new systems aim to increase productivity and efficiency, while the company offers value and individual solutions to the mining industry

Endorsed by In sid e M in in g 0 1 | 2017

editor's comment

Burning bright Publisher Elizabeth Shorten Editor Mientjie Kleinhans Journalist Phila Mzamo Head of design Beren Bauermeister Chief sub-editor Tristan Snijders Sub-editor Morgan Carter Contributors Lorrie Dicks, Rosemary Falcon, Xavier Prévost, Ian Venter Client services & production manager Antois-Leigh Botma Production coordinator Jacqueline Modise Marketing manager Mpinane Senkhane Financial manager Andrew Lobban Administration Tonya Hebenton Distribution manager Nomsa Masina Distribution coordinator Asha Pursotham Printers United Litho Johannesburg Tel: +27 (0)11 402 0571 ___________________________________

he new year often brings with it the winds of change, and it is no different for us. In 2017, Inside Mining will undertake exciting strategic initiatives, at both product and leadership levels. Our objective is to ensure that this publication remains relevant and adds value to our readers’ businesses.

Don’t miss our next edition, where look forward to sharing some of these initiatives with you. Watch this space! Then, as from this issue, we will publish a coal section in every edition that will look at coal mining and aspects of coal processing. Although coal seems to have become a controversial subject when it comes to alternative energy, it is still the cheapest source of energy in Southern Africa. Also, there are enough coal resources left to supply us with energy for decades to come – coal is still alive and well and there is yet much to say about this commodity. We kick off the first official coal section in this edition by featuring articles on stockyard equipment and principles, and tips on maintaining dense-medium cyclones in the coal processing plant. To keep these cyclones in ideal working

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conditions, there are a number of important factors to keep in mind in daily plant

Annemarie Prins

operation. See more about these on page 20.

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South Africa: R550.00 (incl vat & postage) African countries: US$80 Foreign: US$100 Email: subs@3smedia.co.za ISSN 1999-8872 Inside Mining Copyright 2016. All rights reserved. ___________________________________ All material in Inside Mining is copyright protected and may not be reproduced either in whole or in part without the prior written permission of the publisher. The views of contributors do not necessarily reflect those of the publishers.

Sasol’s Shondoni and Impumelelo mines are just about complete, with only a few more projects to finalise. The team at Impumelelo won was lauded for some innovative thinking that saved the mine time and money. The team at Shondoni applied the same methods when they encountered similar challenges that saved it time and money as well. Read more about this on page 26. The Goedenhoop Coal Mine in Mpumalanga is fine-tuned for fine coal, and its dense-medium separation plant delivers higher output than planned, resulting in a huge upgrade in coal beneficiation. Read the article on page 24. Xavier Prévost shares statistics indicating that coal has been the best long-term performing sector in South Africa’s mining industry during the latter half of the 20th century. He goes into detail about the performance and role of coal in South Africa’s economy on page 12. The presence of methane gas and coal dust in underground coal mines has always presented challenges and safety risks, which prompted Coaltech to do extensive research. The Prevention of Methane Ignitions project was born and has subsequently made huge progress in finding the ideal location to place methane sensors on machinery. They have also taken it one step further and have been working on using air amplifiers to boost safety in underground operations. More about this on page 36. We also look at the latest technology and equipment available on the market and find out what’s happening in

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.

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

other mines in Africa. As always, an interesting and varied read.

Mientjie Kleinhans In sid e M in in g 0 1 | 2017

cover story

Adding more value to explosive technology

Offering value and individual solutions to the mining industry, BME’s latest underground suite of services goes beyond emulsion technologies and aims to increase mine productivity and efficiency.

ME recently launched a

explosives industry has been supplied by

range of underground solu-

third parties and challenges have existed

tions using its in-house range

with integrating different technologies and

of emulsion pump technology.

services by third parties to mining opera-

In addition to safety and reliability, the

tions. “By bringing the design and man-

equipment has also been designed to in-

ufacture of these technologies in-house,

- BlastLog tablet

crease the transparency of underground

we are able to reliably integrate and

- BlastLog remote

get maximum benefit

mining operations. The new range includes information systems that record information through

“We try to work as closely as possible with our clients.”

the underground

from each technology.” An example of this

- BlastLog mobile app • Axxis Centralised Blasting System • vertical emulsion pipeline

is the BlastLog system,

• MaxiCharger for narrow reef operations

which allows pump

• new robotic arm for uphole operations

controllers to com-

• low-profile MegaCharger.

pump controller and devices. “By mak-

municate with blast audit tablets and

Among the new solutions is an emulsion

ing information readily available to

provide information to management in

pump technology that increases safety

managers, it is possible to act sooner in

real time through the AXXIS Centralised

and efficiency, while reducing downtime

resolving obstacles to production. The

Blasting System.

and capital requirements. The pumps

systems assist in resolving immediate

used with this technology can be either

day-to-day challenges, while reporting

The new range

on underground blasting efficiency. This

The value-adding technologies that

er, and their size differs according to

allows for the retraining of specific teams

complement the new range of emulsion

operational requirements.

and continuous productivity improve-

technologies include:

ment,” explains Joe Keenan, MD, BME.

• BlastLog information system, comprising:

He adds that, for many years, the

The value-adding technologies that complement the new range of emulsion technologies include the BlastLog tablet

Ins i de Mi n i n g 0 1 | 2 0 1 7

- BlastLog pump controller

hydraulic, pneumatic or hydropow-

The MiniCharger portable charging unit has been developed for narrow reef operations, and the mobile pump (MP2)

cover story fresh look at what is going to happen going forward,” says Keenan. In conjunction with the Rapid Emulsion Delivery System, Mobile Emulsion Transfer Cassettes are utilised for the transport of emulsion from central storage facilities to remote charging units, emulsion distribution tanks and filling stations throughout the operation. Underground filling stations and mobile transfer cassettes are tanks for the storage and distribution of emulsions throughout mechanised and rail-bound underground mining operations. “We try to work as closely as possible with our customers, listen to what their particular needs are and, thereby, develop tools and solutions to resolve

above Operator setting the mass of emulsion pumped between underground storage tanks

challenges from pumps to software to

LEFT The BlastLog system gives client operations access to data as it is captured at the charging face underground by a blast technician using the BlastLog app

technology,” explains Keenan.

know-how. Our customers are constantly challenging us to come up with new

Future of emulsions Keenan says there is a continuous drive to increase the safety of mining operations. “An important part of this is reducing the

and congestion in the shaft. It also results

dangers posed by the handling and use

in reduced labour and operational ex-

of explosives in day-to-day operations.

penses, and streamlined delivery to oper-

Through the adoption of emulsions,

ating sections. The pipeline further allows

mines have been able to move from

accurate recording of explosives distribu-

the use of class 1 explosives to class 5.1

tion from the surface to underground.

oxidisers and, in so doing, increase the

“The conversation with miners has

safety of transportation and blasting.”

changed over the last six to eight

He adds that he foresees autonomous

months. For us, it is about the value that

drills and autonomous loading systems

we create for the miner through new

adding to mine safety, as well as increas-

delivers emulsion at predetermined densi-

technologies. It is not necessarily about

ing productivity and efficiency.

ties for optimum blast efficiency. The MP2

tweaking the formulations; it is about

has been designed with a simple user in-

listening to the customer and solving a

Future plans

terface for mechanical operations.

unique problem. Therefore, we take a

According to Keenan, there are many fu-

5 FACTS

ture plans for the company. “Our primary

These systems can deliver high- and low-density emulsion, even though it requires low energy, making it ideal for mining environments with multiple power sources.

Rapid Emulsion Delivery System In order to transport emulsion safely underground with minimal logistical challenges, BME developed the Rapid Emulsion Delivery System. This vertical emulsion pipeline system proves that BME listens to customers to solve unique problems. “It seems to be simple technology, but it is not. It means transferring the explosives through a pipe, from the surface to an underground tank, and we are constantly trying to expand on that,” says Keenan. Pumping the emulsion through the pipeline frees up the availability of the shaft, reducing explosives care requirements

BME emulsions

focus, domestically, is to increase production capacity and the efficiency of existing capacity. We want to be more efficient and improve our quality even further, because the more profitable we become as

Pumpable emulsions are not classified as an explosive until they are sensitised as they are pumped into the blasthole

an organisation, the better we will be able

ally and already has a presence in Afri-

BME emulsions have high stability and, therefore, a long shelf life

Double-salt formulations have a lower ‘fudge’ point than singlesalt emulsions

to service our customers. Quality is a major driver for cost.” The company is also expanding globca, Indonesia, Australia, South East Asia, Colombia, the USA and Canada.

MegaPump Lateral and MegaPump Uphole are specialised ranges of underground emulsions has developed the longest 5 BME drop emulsion transfer system in the world, measuring 318 m www.bme.co.za

In sid e M in in g 0 1 | 2017

Mining news

from around the continent DRC ENRC investigations

“Cameroon’s transit hubs undeclared”, the group added. CAR, which the U.S. Geological Review ranked the world’s 10th biggest

Eurasian Natural Resources Corp is under investigation for its acquisition of copper and cobalt mining projects in the DRC

diamond producer by value four years ago, has been riven by unrest since rebels overthrew President Francois Bozize in 2013. “While international outcry about ‘blood diamonds’ financing war in the CAR sparked action to stop the trade, the same spotlight has not been turned on CAR’s neighbours,” said Joanne Lebert, executive director, Partnership Africa Canada. “Conflict diamonds still have entry points to international markets through Cameroon,” she added. Trade in the country’s gems was

Democratic Republic of the Congo

UK Serious Fraud Office probes DRC deals

The UK Serious Fraud Office (SFO) is investigating Israeli billionaire Dan Gertler and

banned after the Kimberley Process, DRC are entirely proper and appropri-

which seeks to halt their sale from war

ate. Beyond that, he is not able to com-

zones, as there was no way to determine

ment on allegedly leaked documents,”

if conflict diamonds were being shipped.

said the company.

Cameroon

An understanding was reached in 2015 to allow for the resumption of trade in rough diamonds from “compliant zones”.

Corp (ENRC) executives as part of its

Conflict diamonds entering Cameroon

three-year probe into the Kazakh com-

Conflict diamonds from the Central Af-

pany’s acquisition of copper and cobalt

rican Republic (CAR) are crossing into

Country Mining Vision, a platform for transformation

mining projects in the DRC.

neighbouring Cameroon, and into the

Leaders from different government min-

legal supply chain because of corruption,

istries, members of the academia as well

ities to provide banking and business

smuggling and poor controls, said Part-

as the civil society met to kick-start the

records relating to four DRC-registered

nership Africa Canada.

process of developing the customised

four former Eurasian Natural Resources

The SFO asked the Congolese author-

companies in its investigation into ENRC and nine individuals. They include ex-CEO Felix Vulis; the

Embargoed CAR diamonds are being smuggled across the 900 km border with “large shipments” passing through

Kenya

Country Mining Vision (CMV) for Kenya. The retreat was held in the outskirts of the capital city to discuss a

former head of ENRC’s Africa unit, Victor Hanna; two other ENRC executives; and Gertler and two of his associates, according to a letter from the SFO to the Congolese government. The SFO’s investigation relates to three sets of transactions through which ENRC acquired five mining projects in the DRC between 2010 and 2012. The deals may have violated UK laws including the 2010 Bribery Act and the 2006 Fraud Act, for which individual offenses carry penalties of up to 10 years in prison or an unlimited fine, said the anti-fraud agency in a letter dated 2 September. It was signed by SFO director David Green. Gertler’s Fleurette Group said it wouldn’t comment on the SFO investigation. “Mr Gertler has always made it clear that his business dealings in the

Ins i de Mi n i n g 0 1 | 2 0 1 7

Cameroon Gateway hub for conflict diamonds

South Africa President Zuma optimistic about mining

companies to abide by the rules of their licences, give greater effect to the obligations undertaken in their social and labour plans, and work more closely with government and organised labour to improve the social and economic conditions in all mining areas.

Zimbabwe

Implats and Zimplats approve Mupani Mine South African platinum group Implats and the Zimplats board of directors have approved the development of Mupani Mine at a cost of $264 million. This approval comes after the completion of a bankable feasibility study comprehensive approach on how to

8 January, President Jacob Zuma said the

that will see a new underground mining

address the broad spectrum of the Af-

party was encouraged by the recent rise

complex being developed to replace

rican Mining Vision (AMV) and related

in commodity prices and was relatively

production from Rukodzi Mine and Ng-

issues in relation to the developmental

confident that the South African mining

warati Mine once they are mined out

agenda of the minerals sector in Kenya.

sector would begin to show an improve-

and closed.

The aim of the CMV is to help the country pave the way for a mineral-led

ment in the near future. “The ANC expects to see an increase in

“Approval to construct Mupani Mine is a significant development for Zimplats

structural transformation by improving

production and growth in job creation.

and will ensure we can deliver on our

intersectoral coordination and govern-

We shall remain vigilant in ensuring that

target to mine 6.2 million tonnes per an-

ance, sequencing interventions and

mining communities benefit from mining

num, and maintain production of 260 000

investments better, and to build a broad

activities in their areas. We propose that

ounces of platinum and 220 000 ounces

coalition for change.

all stakeholders engage on how to utilise

of palladium per annum,” says Alex

beneficiation more effectively to ensure

Mhembere, chief executive, Zimplats.

Paul Msoma, governance officer for African Minerals Development Centre (AMDC), said, “This process will, in turn,

economic growth and job creation,” said Zuma.

Mhembere states that design capacity of 2.2 million tonnes per annum is target-

help align Kenya’s related processes to

He noted in his speech that South Af-

the broader AMV agenda, hence ad-

rica’s economy had made rapid strides

vancing an overarching mineral sector

in eradicating joblessness and inequality

framework that adheres to the tenets

when it was growing at an average of

eral reserves by 3 million to 9 million plat-

of the AMV, and gainfully reflects the

nearly 4%, prior to the 2008 global crisis.

inum ounces. At this rate, the new mine

realities and priorities of Kenya, as deter-

The global economic recovery had been

will have a life expectancy of some 25

mined by the country.”

“very unstable” since then, he added

years extracting only the relatively flat ore

As Kenya moves forward towards

“Consequently, as we are connected

ed in 2025 when the full complement of 10 mining teams will be deployed. “The project will increase Zimplats’ min-

reserves,” explains Mhembere.

the domestication of the AMV,

into the global economic system, we

and together with the momentum

have been impacted negatively.

all costs are kept to a minimum in the

generated from the retreat, the Ministry

Investment by the private sector,

constrained PGM price environment,

of Mines and other major players

particularly in developing countries, is

which has necessitated cash preserva-

have pledged to continue rolling

low and trade between countries has

tion strategies across the entire industry.

out the process by creating a clear

fallen. Growth in sub-Saharan Africa is

Against this backdrop, we are delighted

roadmap and continuing support and

estimated to have slowed to 1.4% in 2016

to approve and advance the new Mu-

coordination among key stakeholders.

from 3.4% in 2015. The party is optimistic

pani Mine,” adds Terrence Goodlace,

that the 2017 growth forecast of 2.9% will

chief executive, Implats.

South Africa

Government optimism bridled by caveats

be achieved.” Zuma also stressed that government

“The operation has also ensured that

Goodlace says Mupani will sustain the mining operation well into the future and

would continue reviewing the Mining

will ultimately support the group’s ben-

Addressing supporters at the ANC’s

Charter, and revitalise mining communi-

eficiation strategy through securing the

105th birthday celebrations on

ties. He issued a stern warning to mining

required future pipeline feedstocks.

In sid e M in in g 0 1 | 2017

Hot Seat

New MD focuses on customers The new managing director for Cummins Southern Africa Distribution Business, Thierry Pimi, brings a wealth of experience and unbounded enthusiasm to the role. One of his main goals is to optimise customers’ experiences with the company.

rs, FOCUS on Transport Photograph by Gavin Mye

imi says he is

and capable teams across the regions in

forever grateful to

which he has worked, combining

his customers, and

seasoned industry leaders with exciting

would like to build

new hires equipped with strong local

on the company’s capability

market knowledge and solid regional

to support customers and

business culture.

exceed their expectations.

The new managing director holds a

“I am ready to take up

BSc in Mechanical Engineering from the

the challenge and work

University of Yaounde in Cameroon, an

hard to further enhance

MBA with majors in finance and strategy

the business, elevate the

from Indiana University in Bloomington,

Cummins brand, and get

USA, a certificate in mining studies

closer to our customers. My

from the University of British Columbia

vision for Southern Africa is for

in Vancouver, Canada, and is also

us to exceed our customers’

a graduate of the Cummins Global

expectations through world-

Leadership Development Programme in

class professionalism from a

Johannesburg, South Africa.

diverse and highly motivated team,” says Pimi.

“My vision is for us to exceed our customers’ expectations through world-class professionalism from a diverse and highly motivated team.” Thierry Pimi, managing director, Cummins Southern Africa Distribution Business

Not only was Pimi born

these cycles before in the commodities

and raised in Cameroon,

market. We are currently at the bottom,

he also studied mechanical

but we foresee good trends in the long

engineering there, in what

run. Customers will be here for a good

he refers to as the “Heart of Africa”. He

long time, and they will remember that

conveyed his passion for the company

they have been treated well in the down

at a recent event that announced his

times. That is why we need to take care of

appointment, and he laid out the goals

our customers.”

of his new role. He says that it was an easy

Ins i de Mi n i n g 0 1 | 2 0 1 7

Cummins Southern Africa Distribution

choice for him to join the company, as

Business, backed by Pimi’s proven track

Cummins understands what is needed in

record of leadership and performance

Africa in terms of energy supply.

improvements, is poised to move on to

Pimi took over from Schuyla Goodson

deliver the highest levels of service to its

Bell, who has since assumed the role of

customers. Under his guidance and with

vice-president of Operations: Northern

his extensive experience, the company is

Area, Cummins Pacific Region in the

well set to achieve its targets.

United States of America. Pimi is not new to Cummins. He has held a number of senior management positions at Cummins in the USA and Senegal, starting off as a corporate strategy manager at the company. He is a strong supporter of promoting local talent and has unleashed diverse

Pimi is positive about the mining industry and commodity prices. “We have seen

www.cummins.com

Fossil Fuel Foundation

From heydays to low days Even though coal has seen its heyday and is currently experiencing a dip, it has the potential to be the legendary phoenix rising from the ashes. Professor Rosemary Falcon takes a brief look at the coal industry and its connection with the Fossil Fuel Foundation.

he early 1990s saw a

the different disciplines within the

and energy fields. The FFF has

South African coal industry

coal value chain. This required

also initiated projects such

was flourishing, with

interaction between the

as the South African Coal

successful major mines,

different professions and this is

Roadmap and the Underground

major export contracts for high-

where the Fossil Fuel Foundation

Coal Gasification Association,

value blend coking coal and

(FFF) came into being.

and initiated working groups

high-grade steam products. Major

Initiated by Lionel Falcon,

specialising in specific areas,

new 4Â 500+ GW power stations

president of the Coal Processing

including junior coal mining

were coming on line to service this

Society at that time, he

matters, the geology of coal

rapidly increasing demand.

drew together a group of

and hydrocarbon materials,

professionals from an array

marketing for coal miners,

for greater interaction between

of sources who, together,

industrial boilers, unconventional

the various disciplines in the

provided a band of interested

gas, biomass and clean coal

coal mining and production

parties who then planned the

technologies, and small-scale

spheres and, more importantly,

establishment of the FFF and

industrial boilers.

the customers benefitting from

its future roles. These were

the now varying qualities of

to include the provision of

Coal has started to decline in

products being produced. And

a platform for parties from

popularity internationally and,

so began the need for the first,

different fields to foregather

to some extent, locally due to

real in-depth understanding of

and discuss interrelated matters

the perception that coal-fired

coal qualities and the impact of

including national and regional

power generation causes global

policies and technical issues,

warming. Neither this article

to host conferences, workshops

nor the FFF claim to express an

and courses, and â&#x20AC;&#x201C; in this

opinion on that statement, but

manner â&#x20AC;&#x201C; to provide a basis for

rather the foundation seeks

those in the technical arena to

to provide reasons for the

be made aware of the issues of

continued use of coal and its

the day.

fellow fossil fuels in the most

In 1994, there arose a need

Times are, however, changing.

responsible and environmentally

Technical events

clean manner going forward

To date, between 10 and 16

into the low-carbon future.

technical events have been

It is currently doing this by

held every year along with 7

highlighting the methods by

to 10 industrial courses ranging across all the disciplines in the coal, carbon, gas and related renewable

which to reduce emissions and achieve clean production and usage, to extend into new areas such as co-firing with renewables, and to ensure the socio-economic benefits that this natural and most valuable energy commodity can provide for the foreseeable future.

In sid e M in in g 0 1 | 2017

Economics, finance & risk Statistics indicate that coal has been the best long-term performing commodity sector in South Africa’s mining industry during the latter half of the 20th century, with total annual sales tonnages rising at 4.8% per annum. By Xavier Prévost

Coal’s

powerful role

he domestic market has al-

by cement, chemical feedstocks, the

in prices that reached a low of $49.96/t

ways consumed most of the

metallurgical industry, and commercial

in December 2015. During 2016, prices

coal mined in South Africa,

traders – mainly for heating purposes.

somewhat increased.

accounting for over 80% of all

Local and export sales earnings were closely matched until as late as 1995,

local sales have enjoyed steady but

and about 70% from 1985 to today. Ex-

when export sales revenue began to

good progress in earnings generated,

port-led demand for coal, in contrast,

outpace domestic sales.

growing at 3.4% and 2.4% per annum

was characteristically sluggish until 1978.

After 1995, international coal prices

respectively. Coal export sales’ max-

Export sales of coal took off in 1979

climbed appreciably with only one

imum contributions occurred in 1985

when demand for thermal coal for use

major setback, the Asian financial crisis

and 2001, while local sales peaked

in power stations rose exponentially as

of 1998/99. Since

a result of increasing oil prices. By the

the new millennium,

mid-1980s, export tonnages accounted

rampaging de-

for about 30% of the country’s total

mand from China

coal output. Domestic sales tonnages

and other Asian

of coal have grown at 3.6% per annum

countries has pro-

and export sales at 1.2% per annum

pelled coal prices

since 1983.

even higher, until

Local coal market Some 65% (120 Mt) of the coal consumed each year domestically is

2013, when China’s new policies were implemented. The API4

used to generate electricity. Synfuel

(6 000 kcal/kg NAR

production accounts for 23% (40 Mt),

FOB RBCT) index

while the balance of supply is taken up

shows that in July

In approximately 20 years from now, the Central Basin – the mainstay of coal production in South Africa – is going to be largely exhausted

2007, seaborne coal prices reached an all-time peak of $167.75/t. There-

1997 and 2004. Currently, inland prices impove yearly. South Africa exports coal to Atlantic and Pacific markets and, hence, experiences the same price levels as all other exporters. What is different here is that we have a strong local market that, during 2015, generated R56.6 billion,

while exports only produced R46.9 billion, 17% less. During the years when coal exports were the mainstay of the

in May 2009, to increase again

industry, from 1996 until 2013, exports

very good price. The industry should have ben-

revenue was 36% more (in 2008) than inland sales. Some countries with high exports but lower local sales cannot

efited a great deal,

cut exports and use more coal local-

as we then still had a

ly. Indonesia is now doing that, by

large market in the EU,

increasing its local power generation

but we failed to do so

and reducing exports.

because of insufficient

Ins i de Mi n i n g 0 1 | 2 0 1 7

in value in 1992,

after, prices decreased to $58/t to $124/t by April 2011 – a

In real rands, both coal exports and

the coal produced annually until 1978,

South African coal output was sup-

rail capacity. Since

posed to peak in 2010. Thereafter, an-

2011, there was a

nual production was going to decline

steady decrease

slowly. It is anticipated that the main

Economics, finance & risk

feature of this decline in production will

increase in power demand. Further-

be the closing of the current large oper-

more, the new mines will supply at

ations owned by Anglo Coal, Glencore

least 10 Mtpa or more per power

and South32, and the fragmentation of

station. The new mines are in

resources into smaller blocks – currently

the Central Basin, Mpuma-

the domain of some 44 small mines.

langa and the Waterberg

These fragmented operations will be

coalfields, where the largest

unable to match the output of the

remaining coal resources in

mega mines, which have a yearly pro-

the country exist.

duction of some 10 Mt each, accounting for about 80% of the annual South

New developments

African output.

Despite the more economically

Coal for power

Grootegeluk Mine

marginal expectations associated with making new investments to devel-

In approximately 20 years from now, the

op the Waterberg, Exxaro has a large

current reserves in the Witbank, Highveld

colliery there – Grootegeluk Coal Mine

and Ermelo coalfields (Central Basin),

near Lephalale, formerly Ellisras – to feed

new areas for the development of high-

the mainstay of coal production in South

the Matimba Power Station. This com-

ash, low-quality mines, apt to supply

Africa, are going to be largely exhaust-

plex was established in 1980, and almost

steam coal to nearby power stations.

ed. One possible solution to maintain

doubled in production during 2011 with

A study prepared in 2011 identified a

South Africa’s position as a major coal

the opening of a second section, to

33.9 Mt in situ resource.

producer will be to develop other coal-

provide coal to Medupi, the new Eskom

fields. However, the lack of infrastructure,

power station.

depth of mining in certain coalfields,

Exxaro has recently developed a

It will be possible to supplement and ultimately increase coal resources by developing coalfields in the Limpopo

distance from industrial centres and

plan for the Waterberg, which has

province, even though that would en-

export terminals, and poorer grades of

two main phases:

tail increased production costs because

coal throughout all suggest that it will be

1. A brownfield expansion of the current

of poorer grades of coal, lack of infra-

costlier to generate electricity from coal

Grootegeluk Mine, which will supply

structure and higher transport costs due

mined elsewhere compared with the

feed to Medupi as well as supply

to the greater distances involved from

Central Basin.

products to other markets.

industrial centres and export terminals.

South Africa’s current electricity supply

2. A greenfield expansion, Thabametsi,

The writer holds out for a positive role

is derived from giant coal-fired power

which will entail a new coal mine (IPP)

for coal to play in the future. The fur-

stations, most of which are concentrat-

coupled with a new power station

ther development of the Waterberg

ed near or within the Central Basin. They

and supply significant tonnages to

has already started and it is believed

form the base of the country’s energy

other markets in South Africa.

that, higher costs notwithstanding, the

supply while smaller coal-fired power

The success of the venture will depend

full potential of this coalfield to supply

stations and the Koeberg nuclear power

on the availability of water and rely on

South Africa with some of its coal needs

station supply electricity to the national

the construction of a new rail link via

might be developed. Ultimately, coal

grid at peak power demand.

Polokwane and Burgersfort.

is expected to

The forecast peak capacity needed

In summary, under a scenario based

remain a major

for 2022 is 55 GW. To meet this expecta-

upon future power generation relying

player in con-

tion, previously mothballed small power

on increasing contributions of coal feed-

tributing to the

stations, each supplying a few giga-

stock from the Central Basin, one would

industrial and

watts have been recommissioned but,

expect coal mining and electricity gen-

overall economic

unfortunately, their capacity will not be

eration through conventional coal to

growth.

sufficient over the long term. Hence, two

play a diminishing role in South Africa’s

additional power stations using more

economy over the long term.

than 10 Mt per annum have been implemented to cater for the anticipated

The Vereeniging-Sasolburg, Free State and South Rand coalfields are potential

*Xavier Prévost is a senior analyst at XMP Consulting.

In sid e M in in g 0 1 | 2017

Coal Processing There is much debate in the mining industry about whether raw material stockyards are needed. Lorrie Dicks* believes that without such a stockyard, one cannot ensure a constant feed and grade of material to the process plant.

Stockyard principles

here are various ways

ships, trains and trucks, or to allow for

consider future developments that

that material can enter the

downstream constant material flow and

might be required and how best the

stockyard to provide feed into

quality or for plant process maintenance

stockpiles and stockyard should be laid

the process plant. With the

to be carried out. When loading out to

out â&#x20AC;&#x201C; all of which are vital.

possibility of varying properties/grades,

ships and trains, there is a certain set

and compositions all being delivered

time to load the train and ships, and thus

Storage type selection

into a stockyard, the discussion then

even the actual sizing of the stockpiles

There is a global push towards closed,

is about whether further blending or

becomes critical because all stockpiles

covered, or stringent dust control in

homogenising is required; something that

have lead-in and -out times. During

open stockyards to meet environmental

can be debated for hours with respect to

those lead-in and lead-out periods,

and climatic conditions. In general

selecting the most optimised solution. The

the actual reclaim capacities can be

more attention needs to be given to

goal of a raw material stockyard is to shift

reduced dramatically.

the important issues of dust and the

from discontinuous to continuous material flow with constant quality/grade being

create emergency material stockpiles.

delivered into the process plant.

Storage also allows for the opportunity to

possible environment damage when designingÂ stockyards. Another factor to keep in mind when

control material size distribution and to

planning storage is space availability.

sees different products produced, all of

homogenise raw material, which is the

Stockyards are often constrained

which must be stored. From there on,

control of the raw material properties

because of the overall area allocated

they need to be loaded out as quickly

supplied into the stockyard.

to the processing plant, and thus

The back end of the process plant

as possible. Therefore, the back end

More reasons for storage are to blend

the total area needs to be fully

often has larger capacity stockyard

two or more grades of raw materials

optimised. To compensate for

equipment to load the equipment used

on the same stockpile, and to smooth

geotechnical site conditions,

for delivery to customers.

the material flow and control through

one also has look at where best

a process. Material can also be

it can be laid out, as it is not

Why do we need storage? The need for storage requires careful consideration. The first aim, and an

Another reason for storage is to

segregated into separate stockpiles, with sizing or grade being critical criteria. Then, of course, storage allows for the

important reason, is to disconnect one

future upgrading of plant and processes.

process from another and thus act as

Unfortunately, when stockyards are

buffer storage for material load-out to

laid out and sized, people often donâ&#x20AC;&#x2122;t

Ins i de Mi n i n g 0 1 | 2 0 1 7

*Lorrie Dicks is an independent materials handling consultant servicing the mining industry.

Coal Processing Storage characteristics Longitudinal storage Longitudinal stockpiles are suitable for the direct feed of free-flowing materials. A high degree of homogenisation is also possible in longitudinal stockpiles. The capacity of longitudinal storage may easily be expanded at minimum costs, which is a big plus. Something often overlooked is that the recommended length-to-width ratio of

Numerous operations in Europe are totally enclosed; the only time people enter the space is to perform maintenance

stockpiles for longitudinal stockpiles the rule of thumb is a minimum of the length being 3:4 times the width of the stockpile.

longitudinal storage, but is practically

It is possible to have a non-standard

an unending stacking and reclaiming

wide stockpile, but this generally relates

process with no stockpile lead-in and

to heavier stockpile machinery, which in

lead-out. Also it alleviates the dead

turn relates to higher capex costs.

time when moving from one stockpile

Longitudinal storage can take the form

to another, while loading out or

of open storage, with a luffing or slewing

feeding a process plant. Therefore,

stacker, or roofed storage, with a stacker

it is a never-ending stockpile, as it is

or tripper car for feeding the storage. It

possible to reclaim from the back end

allows for generally low dust emissions

and stack from the front end.

during stacking and a high material recovery rate of up to 97%.

It is also a fully automatic operation. Numerous operations in Europe are totally enclosed; the only

Circular blending storage

time people enter the space is to

Circular blending storage is becoming

performÂ maintenance.

more popular, as it can be closed off. The concept is comparable with

always possible to have an ideally sited stockyard.

stacking methods Chevron

Circular blending storage allows for optimised feeding and the discharge routing of conveyors as one can determine where best to feed in and where best to feed out in a circular stockpile, which is a great advantage. The issue is that circular stockpiles are

Sizing of storage

not cheap and the civil works required is generally expensive.

When designing storage facilities

With circular blending storage, there

for a plant, it is important to bear in mind that storage needs to

is a high availability of stored material

accommodate the longest downtime

in case of an interruption in feeding,

of the preceding or following

and a high recovery rate.

operation. One of the issues that we find quite interesting is what

Windrow

Stacking methods

I term â&#x20AC;&#x153;stockyard constipationâ&#x20AC;?.

The basic stacking methods for

When sizing a stockyard and looking

longitudinal storage are chevron,

at an operation, there is only one

windrow, strata and cone shell. The

rule: to balance the process where

selection of stacking method depends

flow in equals flow out over a given

on what blending or homogenising

time frame. Without this balance,

is required. Stacking methods need

stockyard constipation occurs.

to be considered carefully, as all of

The size of the storage space needs to accommodate the throughput

Strata

them have cost implications. There are four different types of longitudinal

differential of the preceding and

stockyards: triangular-parallel,

following process. In coal-fired power

triangular-in-line, trapezoidal-parallel

plants, the capacity of storage is

and trapezoidal-in-line.

generally between 30 days to 60 days of the power plant coal consumption.

Benefits

That is more or less the rule of thumb.

The benefits of longitudinal stockyards

The larger the capacity of the

include high storage capacity, the

stockyard, the higher the capex. One thus has to look at what is the optimum size for sizing the stockyard.

Cone shell

possibility of future extensions, and the ability to store various material grades or products.

In sid e M in in g 0 1 | 2017

Coal Processing

Stacking equipment for stockyards

There are various kinds of stackers and reclaimers available for selection in stockyards. The common misperception is that a stacker is a stacker and a reclaimer is a reclaimer. Lorrie Dicks* discusses stockyard equipment.

it slews through the stockpile, and oper-

bucket-wheel stacker/reclaimer is the

keep certain factors in mind when

ates from one side of the stockpile and

ideal machine when continuous stacking

selecting equipment for stockyard

progresses through the stockpile in verti-

and reclaiming is not required to be car-

facilities. From the type of stockyard

cal and horizontal index steps. Although

ried out simultaneously and thus allows for

envisaged, feed in and feed out rates,

it can move up and down the stockyard

a cost-effective solution. Because of the

blending/homogenising requirements,

for repositioning purposes, it will reclaim

required boom length for reclaiming, all

to cost, the type of material handled,

from the one end of the pile. Boom

stacking options are available.

and space availability, all are factors

lengths of 65 m are not uncommon, and

to be considered regarding stockyard

the longer the boom length, the heavier

equipment selection.

the machine gets, which increases capex

Bridge-type bucket-wheel reclaimer

costs. If one doesnâ&#x20AC;&#x2122;t have the optimum

The bridge-type bucket-wheel reclaimer

length available for the stockpiles, the

operates in longitudinal stockyard where

The function of a stacker is the storage

stock piles will have to be wider, which

the pile shape is triangular or trapezodial

and blending/homogenising of material

obviously has its own cost implications.

in cross section. Bridge-type bucket-wheel

within the stockyard. Keep in mind that

There are many different designs of

reclaimers are best suited when blending

ith the different

parallel stockpiles, with pile shapes being

The stockyard is again longitudinal, with

equipment options

triangular or trapezoidal in cross section.

single or parallel stockpiles, being trian-

available, it is important

A bucket-wheel reclaimer reclaims while

gular or trapezoidal in cross section. The

for decision-makers to

Stackers

the yard shape can be longitudinal, with

bucket-wheel reclaimers. The pylon

and homogenising is a requirement. Re-

single or parallel stockpiles, or circular with

support type being the most costly but

claiming is carried out by a traversing car

a circular-type stockpile. The pile shape

most compact and best suited where

or cars mounted on a bridge with one or

can be triangular or trapezoidal in cross

machines work back to back and pass

two bucket wheels; the bridge travels in a

section. Stackers offer multiple stacking

one another within constrained areas.

step-by-step motion through the stockpile.

options, depending on boom lengths. The

Other designs include pylon support

longer the boom length, the heavier the

and C-type, which are much more cost-

bidirectional operation rail gauge widths

machine gets and the capex costs rise

effective options

of about 60 m and capacities of more

accordingly. Stackers can be installed externally or within closed structures.

Bucket-wheel reclaimer

Bucket-wheel stacker/reclaimer The bucket wheel stacker/reclaimer is a combination of a stacker and bucket

The buckets are reversible, enabling

than 10 000 t/h are obtainable depending on the material characteristics being reclaimed. Bridge-type bucket-wheel reclaimers

With a bucket-wheel reclaimer, the

wheel reclaimer, which either stacks or

are constrained by the stockpiles wherein

yard shape is longitudinal, with single or

reclaims at any one time.

they operate and thus cannot move up

Ins i de Mi n i n g 0 1 | 2 0 1 7

Coal Processing

OPPOSITE PAGE Circular stockpiling and reclaiming right Longitudinal bucket wheel reclaimer in the foreground and a stacker in the background

A particular benefit of automation is 24/7 unmanned operation in nearly all weather conditions

and down the stockyard as per stackers,

of the stockpiles. Clients want to know

at their ultimate performance and

bucket-wheel and portal reclaimers.

what is on their stockpiles, and where to

loading capacities.

Portal reclaimer Portal reclaimers are more commonly found operating in less abrasive

start reclaiming from to ensure that what

It is also possible for one operator to

they feed into their plant or despatch is

remotely control all the stackers and

of a constant nature.

reclaimers from the central control room.

Environmental challenges, such as

The throughput of an automated oper-

materials than those handled by bucket-

weather and dust play a big role in

ation is equal to or even better than a

wheel reclaimers.

maintaining performance, and there is

manual one and there is a definite re-

dire need for increased personnel and

duction in maintenance costs, as there is

equipment safety.

no abuse of the machines.

The portal reclaimer features a portaltype bridge, luffing scraper boom, or a split boom in a single- or double-boom

A solution to many of these challenges

format. Reclaiming is undertaken while

lies in automated systems, which are

Complete solution

travelling longitudinally along the

operated totally from a remote location

The current trend is to be able to blend

stockpile. Reclaim rates of 3 500 t/h are

and where one can determine what is

and optimise the material by making use

possible with a double boom depending

on the stockpile and stack and reclaim

of analysers. The material going into the

on the characteristics of the material

from the information provided.

stockyard can be analysed and then

being handled. Indoor installation is possible with this

directed to the correct stockpile. The

Automated benefits

complete solution is a system that can

type of machine and rail gauge widths of

A particular benefit of an automated

visualise what is on the stockpile and

about 60 m are not uncommon.

operation is 24/7 unmanned operation

what the stockpile capacities are.

Operational challenges for stockyards There are various operational challenges

in nearly all weather conditions. Automated operation facilitates high

*Lorrie Dicks is an independent materials

system availability and performance,

handling consultant servicing the

meaning the machines are operated

mining industry.

for stockyards when considering equipment. Challenges include unstable operator and process performance. Operators do not always operate at 100% efficiency and the machine’s performance is thus negatively affected.

Table 1 Comparison: lateral/travelling scraper reclaimer and a bucket-wheel reclaimer

Property

Scraper reclaimers

Material Grain size Up to 150 mm properties Abrasive Applicable

Another challenge in the industry is op-

Up to 500 mm Not applicable

Partly applicable

Not applicable

Capacity

Up to 3 500 t/h per boom

≥12 000 t/h

Reliability/availability

Good

Better

maintenance, and unscheduled mainte-

Maintenance

More maintenance required

Less movable parts

nance can also be caused by overload-

Operation

Equalised output rate

Average capacity 65% to 80% or the nominal capacity

erator “error”, which renders machines unserviceable. Sometimes, machines are intentionally abused, requiring additional

Sticky

Bucket-wheel reclaimer

ing of the equipment. There is also limited data available relating to the actual dimensions or contents of stockpiles, and final quality

Price

More expensive

Stockyard machine capacities are based on volumetric principles (bulk densities and grain size).

In sid e M in in g 0 1 | 2017

Coal Processing

Charting a

water-secure future

Facing perhaps the worst drought in a century and bearing the yoke of treating acid mine drainage (AMD) caused by over a century of gold and coal mining activities, South Africa’s mining industry is already a world leader in treating water to drinking quality standards.

peaking at the 360° Mining Per-

“We will see more treatment of AMD in

spectives seminar hosted by SRK

these areas,” he said. “South African

Consulting in Johannesburg last

expertise has proved that it can be done

year, the company’s principal sci-

on a large scale, and it is becoming an

entist, Dr Andrew Wood, said no country in

important aspect of addressing both the

the world was faced with the sheer volume

water shortage and the environmental

of AMD as South Africa, or the challenge of

issues related to AMD.”

making it fit for human consumption.

Under pressure He said the mining sector consumed

“Many mining companies are taking the

from government that a long-term plan

just 3.3% of the country’s water – com-

initiative and installing technology-leading

costing R12 billion would soon be rolled

pared to agriculture’s 60% and energy’s

and innovative treatment plants,” said

out to tackle AMD on the Witwatersrand.

4.3% – but, again, the mining industry is

Wood. “A successful joint project between

However, he cautioned that the mining

under considerable pressure to reduce

mines in Mpumalanga is already providing

sector is expected to meet two-thirds of

its usage. The Minister of Water and San-

potable water to the communities around

this cost, despite the reality that most of

itation recently urged all mining houses

the town of eMalahleni – and this supply

the companies responsible for the prob-

to use water sparingly in their operations

will endure well beyond the life of the

lem are now defunct.

in the light of water shortages across

mines themselves.” He said the threats posed by AMD are

He noted the recent announcement

Acid mine drainage – as seen in these images near Johannesburg – is not limited to the historic mining areas of the Witwatersrand, but also affects a number of other provinces

“Furthermore, this R12 billion refers only to the current project cost,” said Wood.

the country, but specifically mentioned Rustenburg’s platinum belt.

not limited to the Witwatersrand, where it

“There will still be substantial long-term

had tended to attract the most publicity

operating and maintenance costs to be

bomb is materialising, posing a grave

and concern; the provinces of Mpuma-

quantified, so the implementation of this

risk to mining,” Wood said. “The avail-

langa, Free State and KwaZulu-Natal also

plan – and its extension to other areas of

ability and quality of water was one

face material AMD risks.

AMD concern – will not be easy.”

of the major concerns highlighted in

Ins i de Mi n i n g 0 1 | 2 0 1 7

“South Africa’s ticking water time

Coal Processing “The reuse of treated sewage has been conducted in countries like Namibia and Singapore for decades.”

Dr Andrew Wood, partner and principal scientist, SRK Consulting

Underground storage is also a strategy being employed by some South African mines, and is used extensively in China, where excess water is stored in minedout underground workings for industrial and other purposes – a cost-effective alternative to constructing surface dam infrastructure.

Licencing PricewaterhouseCoopers’ 2015 edition of

supply by 2025. In this context, the mining

Wood raised the issue of water use

‘SA Mine’.”

sector had markedly improved its water

licenses (WULs) and noted, “Of the

management practices, he said.

103 mines operating without valid WULs

He said the country had known for many years that it would be in crisis mode

“At mine level, our solutions are becom-

in mid-2014, 55 of them have applied

by now; Gauteng’s water demand has

ing more advanced, with greater use of

for licences. Mines are all required to

already technically outstripped supply,

computer modelling software to improve

have WULs and are obliged to comply

and the province can now sustain itself

management’s options and to optimise

with the conditions; but, in many

only through growing imports of water

water usage,” he said. “Attention is par-

cases, the mines cannot comply with

from the Lesotho Highlands Water Project

ticularly focused on optimising mine pro-

all the conditions as some are so oner-

and other catchment transfer schemes.

cessing plants and concentrators, where

ous that they make compliance practi-

much of a mine’s water is used simply to

cally unachievable.”

“The second phase of the Lesotho Highlands Water Project was due to come

transfer tailings in slurry form to the tailings

online in 2019 to bring clean water – es-

storage facilities; the aim is to achieve

tion has reported that it had completed

sentially AMD dilution water – to Gaut-

dense tailings reporting to the dumps, not

investigations into 81 WUL cases, and

eng, but this has been delayed for at

diluted water.”

was continuing with another 23; it had

least another six years, which reduces our

Satellite imagery is being employed to

The Department of Water and Sanita-

also issued 43 notices and 12 directives,

availability,” he said. “Some dams have

assess climate change implications for

while opening six criminal cases against

been constructed, such as De Hoop Dam

mine water management and better

mines for lack of compliance.

in Limpopo, which will feed some mines in

understand present and future water

He also highlighted the growing role

the area; however, some of the intercon-

balances on mines and how to better

of groundwater in addressing national

necting pipework and associated infra-

manage water – especially tailings

shortages. “While many small towns are

structure is still to be put in place. The cost

water management. The failures of tail-

reliant on groundwater, the country has

of this water to consumers is significantly

ings dams on mines – such as the 1994

previously not harnessed the full value

greater than the cost for water that has

Merriespruit disaster in the Free State

of our large groundwater resources –

historically been provided, in order to

and more recently at Samarco mine in

and we will need to investigate

recover the practical costs of such new

Brazil – highlight the fact that substantial

and manage these more

bulk water supply infrastructure. Installing

human life and environmental risks still

effectively in future,”

bulk infrastructure is an important strategy

exist in this field.

he said.

pursued by the country; planning is well advanced and we generally know what

Recycle and treat

is needed, although financing and imple-

South African mines are also increas-

mentation are the challenge.”

ingly recycling water on-site, and are

The much publicised War on Leaks

likely to move towards the more sophis-

government initiative and the training

ticated desalination plants in the near

and employment of 15 000 plumbers as

future, to further close the loop within

announced during the president’s State

mining operations and minimise water

of the Nation Address, will also make up

consumption.

vital components of water conservation,

Wastewater recycling is likely to

as South Africa loses 37% of its treated

become a more important option

water through leaks and non-payment by

for the country, in general, as

users, he said.

demand grows.

Managing the balance

has been conducted in coun-

“The challenge of matching supply with

tries like Namibia and Singa-

demand continues to grow, as the pop-

pore for decades,” he said.

ulation of Gauteng expands alongside

“Even South Africa does

rising expectations of access to water by

it already in an indirect

households – separate from industry and

way: a substantial portion

agriculture,” said Wood.

of the water that comes

The country as a whole faces shortag-

“The reuse of treated sewage

back to us from the Vaal

es – with forecasts showing that South

Dam is sewage effluent

Africa’s water demand would exceed

from Johannesburg.”

In sid e M in in g 0 1 | 2017

Coal Processing

Prolonging the life of

cyclones

Multotec high-chrome MonoCone DMS cyclone

Dense-medium separation using cyclones is a complex process. Proper preventative maintenance is required to optimise operational efficiency, writes Mientjie Kleinhans.

ceramic-lined cyclones are used. “There should be protection against oversize particles that are too large to be processed by the cyclone unit in order to avoid blockages. And a working pressure transmitter or pressure gauge will assist in determining if the volumetric

ravity differences play

“Heavy particles sink through the dense

flow rate to the cyclone unit is consist-

a big role in dense-medi-

liquid and light particles float,” writes

ent,” he explains.

um separation (DMS) – the

Bornman.

process of separating

To keep dense-medium cyclones in

Another important factor to keep in mind is the proper maintenance and

valuable material from waste. Faan

ideal working conditions, there are a

operation of drain and rinse screen pan-

Bornman, technology manager, Mul-

number of important factors to consider

els, magnetic separators, and pumps.

totec, describes in his technical paper,

in the day-to-day operation of coal

“The densitometer and pressure trans-

‘Practical Operational Aspects of

dense-medium processing plants.

mitter should be calibrated on frequent

Dense Medium Cyclone Separation’*,

Bornman explains that one such factor

intervals to ensure accurate readings,”

that the specific gravity difference be-

is that mines should ensure there is

says Bornman.

tween the two fractions must be large

proper oversize protection from foreign

enough to achieve high efficiencies.

objects – e.g. steel – in the case where

Ins i de Mi n i n g 0 1 | 2 0 1 7

He adds that proper inspection at frequent intervals throughout the

Coal Processing

thus allowing for extended use of the

ABOVE Faan Bornman, manager: Process Equipment Technology, Multotec

complete cyclone.” Bornman says that the life of a cy-

RIGHT Multotec DMS cyclone vortex extension

clone will be shortened when the cy-

FAR RIGHT Multotec high-chrome MonoCone DMS cyclone

clone runs at excessive pressure. “Wear rate is a function of the change in operational pressure to a power factor of

operational life of the unit will ensure the

for clients to try. “Some of this material

2.5. If the operating pressure doubles,

internal integrity of the unit, and proper

may, however, not behave as expect-

the wear rate increases fivefold.”

desliming upfront from the cyclone unit

ed in a dense-medium environment

will prevent misplaced fines.

and it is, therefore, always good to first

Cyclone types

When the cyclone is pump fed, it is

try it on a smaller part of the cyclone.”

There are various types of cyclones for

important to check for impeller wear

Clients sometimes replace the whole

different applications, and it is benefi-

and a decrease in operational pres-

cyclone after they have noticed that

cial to use the correct cyclone originally

sure. “Also, ensure that the pressure

the spigot has worn to unacceptable

designed for the processing plant. “In

gauge is present and in good working

limits. “In some cas-

condition. Check for wear in the inlet

es, the remaining

nozzle, inlet head, lower cone, and

part of the cyclone is

spigot. Both the cyclone and the sup-

still in an acceptable

port system, such as the plant around

condition and could

the cyclone, should also be in a good

still have been used.

operational condition.”

Suppliers like Multo-

Wear rate

tec supply oversize spigots, which cater

It is possible to prolong the life of a cy-

for these options,

clone in DMS by following a few steps.

where only the spig-

Bornman says that there is alternative

ot is restored to its

wear material available on the market

correct diameter,

The life of a cyclone will be shortened when the cyclone runs at excessive pressure

DMS, it is of utmost importance to ensure the cyclone diameter matches the solids feed rate and correct medium-to-ore ratios. Similarly, the cyclone should be operating at the correct operating head (pressure). A mismatch cyclone does not achieve these objectives.

Maintenance According to Bornman, maintenance should preferably be done on every maintenance shutdown in order to allow for internal inspection, adding that the inspection should include: • Monitoring the internal condition to determine if there are any abnormal wear patterns forming, or in the case of a ceramic cyclone, if any tiles have been damaged • Measuring the spigot diameter since the cyclone efficiency can become affected as the spigot diameter increases • Looking at the vortex finder leading edge, which means looking from the spigot side into the vortex finder, to determine if the condition is still good. In the event that it is not possible to inspect from the spigot side, the vortex finder length can be measured from the top of the cyclone after the overflow pipe has been removed

• Measuring the vortex finder length and spigot diameter • Checking for excessive grooves in the cyclone body or vortex finder • Checking for inlet and cone wear, uneven surfaces, and steps.

Multotec Max 800 ceramic-lined DMS cyclone

In sid e M in in g 0 1 | 2017

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Coal Processing

Multotec highchrome DMS cyclone

Another possibility can be the design of the mixing box or modifications made to it, which can cause slumping of solids into the suction of the pump,” says Bornman. He adds that one must also ensure that there is enough medium in the circuit to ensure a proper level in the correct medium tank and mixing box. In the technical paper, Bornman writes that slimes, defined as the -45 micron clay particles, cause viscosity problems in the medium, which influences the separation of near-density particles. “It is recommended to add 2 m3 to 3 m3 of water per tonne of coal to the preparation screen for de-sliming. The bed depth should be less than 20 mm, depending on the top size of the feed material.”

Other challenges Two other challenges that mines face are inadequate spares inventory and “The impact of not having the cor-

built-up material, pressure problems and

improper training. “Inadequate spares

rect sized cyclone will result in a loss

inconsistent feed in and/or out of

inventory is one of the problems ob-

of product and, thereby, revenue.

the cyclones.

served in mines. In order to keep costs

In some cases, the client is not even

Bornman says that build-up of mate-

low, low spares inventory is one of the

aware of this loss since the sampling of

rial, also commonly referred to as the

areas that is recommended. We see

these streams is not always done cor-

hang-up of material, can be due to a

that if the spare part is not available,

rectly and sampling errors introduced

too large differential over the cyclone,

no or inadequate maintenance is then

into the results mask the loss of efficien-

which can cause medium instability

conducted on the cyclone. This has a

cy,” says Bornman. He adds that with an incorrect selection of the cyclone, others areas can become affected, like the cyclone feed pump not operating in the correct operating range, drain and rinse screens not been able to perform optimally

“The combined monetary effect of inefficient operation and the cost of breakdowns far exceed the value of adequate spares inventory.”

resulting in medium

inside the cyclone.

sacrificed due to worn parts, which af-

dimensions are fixed,

fects the performance of the unit and,

and at some stage

since maintenance is not done, other

the cyclone has been

problem areas are not identified in time.

operating at the cor-

“Unplanned breakdowns can also

rect pressure, sudden

occur. The combined monetary ef-

changes in operating

fect of inefficient operation and the

pressure would be the

cost of the breakdown far exceed the

result of the cyclone

value of adequate spares inventory.

feed pump not oper-

Proper training on the impact that an

ating correctly. “This is

inefficient cyclone can have on the

not to say the pump

bottom line of a process can help

itself is the problem,

to reignite the effort of doing proper

as the problem often

maintenance on an ongoing basis,”

losses, and increased wear rates inside

manifests itself before the pump – like

the cyclone unit itself, which increases

fluctuating medium additions or solids

cost of ownership.

feed rates into the process.”

There are high-chrome, ceramic-lined,

twofold effect: the cyclone can be

Since the cyclone

When there is inconsistent feed in

concludes Bornman. *‘Practical Operational Aspects of Dense Medium Cyclone Separation’

and silicon carbide cyclones cyclone

and/or out of the cyclones, it is impor-

by Faan Bornman was first presented

parts available. “The benefit of using

tant to remember that the cyclone

at the 46th Annual Canadian Minerals

the correct or ideal cyclone will ensure

can only produce what it receives,

Processors Operators Conference in

the optimum lifetime and performance

and if the solids discharge rates are in-

Ottowa, Ontario.

of the cyclones.”

consistent out of the cyclone and one

Cyclone problems

has confirmed that hang-up is not the problem, then the feed into the cyclone

With DMS being such a complex sys-

circuit is the problem. “Erratic feed to

tem, there will be certain issues caus-

plant tonnages is usually the cause of

ing problems in the cyclone, such as

the cyclone not discharging correctly.

Follow the link For the full paper, go to: http://bit.ly/2iQn4SG

In sid e M in in g 0 1 | 2017

Coal Mining

An output exceeding expectations

A quality processing plant is one that is efficient and flexible in the products it produces, and has a small footprint. Taking quality to the next level, the processing plant at Welgemeend Colliery delivers higher output than originally planned. By Mientjie Kleinhans

elgemeend primarily

each source. Although the plant is actu-

mines two coal seams, i.e.

ally designed at 400 tonnes per hour, we

C-upper and C-lower, of

easily run it at 450 tonnes. We wash for

which 60% of the run-of-

Eskom product on the upper seam, and

mine (ROM) is from the upper seam, and

make size products on the lower seam.

40% is from the lower seam. The plant

Of the fractions, we export the duff

runs at 450 tonnes per hour on the upper

product,” says Ian Kitchenmaster, plant

seam and 350 tonnes per hour on the

manager, Fraser Alexander.

lower seam. The lower seam is the better quality

The plant was built to be fit for purpose. According to Kitchenmaster,

ABOVE On the left is the current crushing system with the new crusher being built on the right BELOW Fraser Alexander’s Stefan van der Walt, business unit manager, and Ian Kitchenmaster, plant manager

drum plant were constructed in the second phase. The plant started production on 15 June 2015.

seam, and it is the deeper one of the two

the plant’s footprint is small, yet it is able

seams, while the upper seam is typical

to achieve the same results as some

section in the first phase. We used mobile

Eskom product. There are six opencast

other bigger processing plants. The

crushers to run the plant,” says Van der

pits, of which the deepest is 20 m, and the

small footprint impacts on the amount

Walt. He adds that the original mine plan

average trip ratio is 3:1.

of capital spend, and the number of

was to produce around 200 000 tonnes

people employed. “From that point, it is

per month run-of-mine coal. “The target

just much more efficient when looking

is now 240 000 tonnes per month and we

at the fit-for-purpose type of operation.

have exceeded the 250 000 tonnes per

With the plant’s flexibility, we can

month mark twice.”

“The yield varies on the different seams; therefore, we run different inputs rates on

produce any kind of coal product,”

“There wasn’t a run-of-mine crushing

“The plant was designed to be flexible,

says Stefan van der Walt, business unit

cost-effective and legally compliant,”

manager, Fraser Alexander.

explains Kitchenmaster.

The processing facility was built in two phases. The cyclone plant with

Fine coal plant

1 000 mm DMS cyclone, the fine coal

Another fact worth mentioning is the

plant and the filter press plant

operational fine coal dense-medium

were built in the first phase. The crushing plant and the

separation (DMS) plant. This plant was designed to process the typical spiral

Coal Mining

fraction of -1 mm, which means all -1 mm material goes through the fine coal DMS process, resulting in a significant upgrade in the coal quality, typically from 16 Mega joule per kilogram (MJ/kg) to 22 MJ/kg for the C-upper seam at Welgemeend Colliery. “With a typical spiral plant, one

ABOVE LEFT The magnetic separator drum in the dense-medium separation plant ABOVE The plant runs off four 500 kVA generators ABOVE RIGHT The 1 000 mm cyclone in the dense-medium separation plant

class, and benchmark in the industry,” boasts Van der Walt.

Challenges The plant started with many challenges in phase 1. The mobile crusher was crushing the coal extremely fine, resulting in oper-

Generators

ational problems with the thickener.

achieves lower upgrade values and it is

Van der Walt says what is also unique to

difficult to adjust the cut point in order

the plant is that it runs off four 500 kVA,

crushing plant was up and running, the

to produce different products. With the

fixed generators. “There are a handful

crushing would improve. The crushing

fine coal DMS plant, on the other hand,

of coal mines that run off generators in

plant was not built from scratch – it was a

one can tweak densities and target a

South Africa. To process 250 000 tonnes of

second-hand plant that we had to make

specific product. The efficiencies of the

coal per month with generators, the gen-

work. Therefore, we had to iron out a few

DMS cyclones are also much higher

erators must be available 90% of the time.

things, such as crusher segments and

than a spiral plant, which results in bet-

“An advantage is that the plant is not

“We always knew that once the

bearings. The crushing plant is high main-

ter yields and higher upgrades,” says

dependant on Eskom power. Other mines

tenance, and due to the upper seam

Van der Walt.

use generators as a back-up only,” says

being abrasive, the material is damaging

Kitchenmaster.

to the plant,” says Kitchenmaster.

He adds that the fine coal DMS plant is one of a handful of operations in

The plant is dependent on the genera-

the country that runs so efficiently.

tors to run smoothly as the washing facili-

Run of mine

As a result, the management team

ty, the fine coal plant, and the filter press

Welgemeend’s run of mine consists of

of the mine is impressed with the

have to be available 95% of the time. If

a jaw crusher as the primary crusher.

plant’s performance.

one of those sections comes to a stand-

-60 mm material is then screened out

still, all production stops. “For instance,

while the +60 mm material goes back to

there is no bypass past the press to a

the double-roll crusher for the secondary

The ultra-fine coal is pumped from the

slurry dam – if the filter press stands, one

sizing to -60 mm. It is a closed-loop crush-

DMS plant thickener to the filter press

cannot get rid of the ultra-fines and the

ing system that operates at 500 tonnes

plant. The team has to monitor and con-

whole operation comes to a standstill,”

per hour.

trol the density of the ultra-fine coal to

explains Van der Walt.

Filter press

ensure a density of 1.12 kg/ℓ for the press

He adds that going from 200 000 tonnes

Future opportunities

per month to 250 000 tonnes per month

An opportunity exists to introduce froth

means getting more hours in a month,

flotation in the near future the will in-

process 25 tonnes of ultra-fine coal per

less breakdowns, and doing mainte-

volve feeding the filter cake through a

hour, and each filter press produces

nance effectively. Where the average

froth flotation plant in order

filter cakes of about 25% moisture, which

would be around 500 running hours per

to upgrade to the

makes the coal cakes manageable. “The

month, the processing facility has

coal cakes fall onto the conveyor belt

been able to exceed 600

and are loaded with a front-end loader

hours per month on a

into a dump truck at the other end,”

few occasions. “To

explains Van Der Walt. Currently, the

get to 600 run-

ultra-fine coal cakes are stockpiled until a

ning hours per

market has been found for the material.

month is world

to operate optimally. Two plate and frame filter presses each

Welgemeend Colliery

9 years

material for the export market.

the number of years the

the deepest opencast

20 m

450 tonnes

mine has been operating

pit at the mine

capacity of the plant

the hourly processing

In sid e M in in g 0 1 | 2017

Coal Mining

Award-winning plans Impumelelo Mine has had an impressive run of late, keeping pace with projected targets and being lauded for its innovative approach. Transplanting the mine’s successful strategy into Sasol sister operation Shondoni Mine has seen the latter get back on track with its own projects. By Mientjie Kleinhans

hondoni and Impumelelo

relocation of production sections from

are part of Sasol’s R15.3 billion

Brandspruit Mine to Impumelelo Mine had

replacement project scheduled

limited float. This constraint made it critical

to be completed by 2018. A

for the project team to remain on sched-

few challenges with ground conditions at both sites potentially compromised

The delays in the shaft-sinking process

meeting project deadlines, but the Impu-

also impacted the construction of the

melelo team’s quick thinking won some

underground bunker. Again, the project

time to get the projects on track again.

team came up with a plan to mitigate

One of the plans that won the team

the potential impact on the relocation of

the innovation award concerned an

production sections. It created a tempo-

incline conveyor belt that was sup-

rary transfer point at the C4 coal seam

posed to move material out of the

to bypass the underground bunker and

mine, but due to the decline shaft be-

moved coal to the surface using the newly

ing late, the conveyor belt had not yet

installed main incline conveyor belt. The

been installed.

team was then able to finalise the under-

“The project team came up with the

ground bunker while the sections were

idea to use the kibble system in the

able to mine simultaneously. The change-

ventilation shaft, which was used for

over from the temporary transfer to the

shaft-sinking purposes, and equip it with

bunker was done over a long weekend,

a feeding conveyor and a rapid loading

preventing production delays and com-

flask to extract the coal from the mine.

pleting the main underground materials

This change created flexibility in the pro-

handling system as planned.

ject schedule. We then hoisted the ma-

“The execution of these changes wasn’t

terial to surface with the kibbles, allowing

as simple as it sounds. To move the scope

the teams to open up the areas under-

of work between different contractors and

ground between the new shafts while

to maintain the energy and productivity

installing the incline conveyor. By doing

levels required to meet the schedule, you

that, the teams managed to get back

need a dedicated owners and contrac-

on schedule,” says Johan Duvenhage,

tors team supporting the intended goals,”

programme manager, Sasol Mining.

says Duvenhage.

Impumelelo Mine is the replacement

ule to prevent production losses.

mine for Brandspruit Mine. To optimise

Two phases

reserve utilisation and to prevent new

The Impumelelo project was split into two

capital spent not being utilised, the

phases to optimise the phased relocation

Ins i de Mi n i n g 0 1 | 2 0 1 7

10 1

Shondoni & Impumelelo

FACTS

he incline conveyor shaft T at Impumelelo is 17 degrees, compared to the 12 degrees at Shondoni

Impumelelo project 2 commenced in January 2011

I mpumelelo’s incline shaft is 235 m deep, 1 000 m long, 6.5 m wide and 3.5 m high

I mpumelelo’s ventilation shaft is 210 m deep and 6.6 m in diameter with two fans

Impumelelo’s overland conveyor belt is 27 km long

Shondoni construction commenced in February 2012

Shondoni’s overland conveyor belt is 21 km long

S hondoni’s ventilation shaft is 120 m deep and 9 m in diameter with three fans

S hondoni’s winder and elevator shaft is 150 m deep, 11.7 m in diameter, and can accommodate 200 people

asol’s project includes the 10 Sreplacement of three mines, high wall access, social and labour plans, and local economic development plans

Coal Mining

OPPOSITE PAGE Coal is fed directly from the Brandspruit bunker to Sasol Synfuels

well as the upgrading of a provincial ac-

longest single-flight overland conveyor in

cess road, an electrical ring feed supply,

the world, with a length of 27 km. The designed capacity of the overland

and a second ventilation shaft system. plan. The first phase, which comprised the

The ventilation shaft and the main under-

system is 2 400 tph of coal, and it is op-

entire main infrastructure to support the

ground substation are on the critical path

erated at 2 000 tph, running at a speed of

mine and the relocation of the first five

and the construction of both activities

6.5 m/s. The overland system has trans-

production sections, has been completed.

have commenced.

ported more than 3 million tonnes of coal

The first production section commenced in

to date.

January 2015 and the mine was handed

Conveyor system

over to the Mining Division in October 2015.

The Impumelelo materials handling system

Shondoni

The underground bunker was operational

comprises an underground bunker, seven

Shondoni experienced the same chal-

in May 2016.

conveyors and two surface bunkers. The

lenges as Impumelelo and Thubelisha

two surface bunkers, 15 000 tonne and

with moving coal to surface before all the

achievement in completing Phase 1 of

4 000 tonne, respectively, have been con-

underground infrastructure were complet-

the project within its budget of R4.65

structed using a combination of cast in

ed, and therefore implemented the same

billion. To achieve optimal construction

situ and precast concrete panels and the

strategy. “This immediately freed extra

boundaries between Phase 1 and Phase

project received a commendation from

time for the project to be completed while

2, more buildings and change houses

the Concrete Society of Southern Africa.

production sections could be relocated

were built as part of Phase 1 than origi-

The materials handling system boasts the

in time without production loss,” explains

The project team is proud of its

Marius Kruger, programme manager,

nally planned. This resulted in savings for Phase 2, reducing the required capital from the originally estimated R1.5 billion to R867 million,” explains Duvenhage. Phase 2 of the Impumelelo project consists of the relocation of the remaining production sections with associated infrastructure, offices and change houses, as

BELOW Shondoni’s overland conveyor system on the left joins Impumelelo’s conveyor belt at the Brandspruit bunker

Sasol Mining. The first phase was concluded early in 2016 and the final project handover took

bottom left Coal stockpiles at Shondoni Mine

place, with the big move successfully

BOTTOM RIGHT Shondoni’s finished bunker

operation, with the only outstanding con-

Did you 66 km know?

the total distance of overland conveyor

happening in April 2016. The mine is in full struction activities being the second half

45 million

the estimated hours of work done on this project

43 km

the total distance of roads built

In sid e M in in g 0 1 | 2017

Coal Mining

“With all the settings being finalised, it is expected that the conveyor system will reach at least 98% availability.” Marius Kruger, programme manager, Sasol Mining

of the incline conveyor belt. The first half of the conveyor currently moves coal from two sections. The outstanding part is the bottom section of the bunker and the final stretch of the incline conveyor extension underneath the bunker, which will move coal from seam 4 to surface. Completion of the bunker is set for July 2017 and the entire system should be operational and commissioned on 1 August 2017. The project team is on track and fore-

TOP The bunker at Impumelelo looks very similar to Shondoni’s

settings being finalised, it is expected that

ABOVE Impumelelo’s 28 km overland conveyor

98% availability,” says Kruger. Coal from two sections is presently brought to surface at Shondoni and

cast to complete the project within the approved budget of R5.64 billion.

which complicated the commissioning

coal from the remaining seven sections

“Competitive market conditions played

process. We had to handle much more

is brought to surface at the existing Mid-

in the project’s favour, with construction

coal than anticipated, but we overcame

delbult mine. As of 1 August 2017, a third

companies quoting aggressively to secure

the challenge by negotiating time slots

section will be relocated to Shondoni, and

contracts, which resulted in potential pro-

with the operations team to make the

the fourth section will be relocated from

ject savings. The optimisation of designs

system available for the project to do final

November 2017.

also contributed to additional savings,”

adjustments,” explains Kruger.

says Kruger.

On 1 August 2016, the incline conveyor

Surrounding resources

system was commissioned and moved its

The new replacement projects mean that

first coal from underground to surface. The

Sasol Mining will be able to supply Sasol

The project team experienced a few

overland system from Shondoni to Brand-

Synfuels with coal until 2050. In order to

challenges with the commissioning of the

spruit is a 21 km single-flight conveyor belt

further optimise Shondoni’s reserve extrac-

overland conveyor system. Where it initially

without a booster drive. This record-long

tion, Sasol Mining introduced a pre-feasibil-

planned to commission the system with

overland conveyor was commissioned to-

ity study to find the most suitable position

coal produced from only two production

wards mid-August 2016 and experienced

for a satellite shaft. The outcome of the

sections, it had to cope with additional

very little commissioning problems, consid-

study showed that the satellite shaft can

coal being delivered by truck. Additional

ering it is the longest single-flight conveyor

be postponed with three years to 2026.

coal was delivered to Shondoni to main-

in the world. The main cause of problems

“This is of great benefit to Sasol Mining with

tain the Sasol Mining stockpile levels.

was communication loss between the

regard to the postponement of capital

head and tail-end pull-keys. The team

spending. The feasibility study is also post-

coal brought in from other suppliers and

fixed the problems and restored the sys-

poned and will only commence in three

had to handle 200 000 tonnes of coal,

tem to above 90% availability. “With all the

years’ time,” concludes Kruger.

Challenges

“Shondoni is ideally located to handle

the conveyor system will reach at least

Ins i de Mi n i n g 0 1 | 2 0 1 7

MINING IN AFRICA

Gearing towards full production A new cage and a rock-hoisting winder are expected to be installed and operational in 2017 at Ivanhoe Mines’ Kipushi Zinc-Copper Mine in the Democratic Republic of the Congo.

earing towards full

“We are working hard to have

operation by late 2017,

the mine ready to restart pro-

the team at the mine has

duction. Given the extremely

made excellent progress

high zinc grades at Kipushi, the

in upgrading and modernising

mine has the potential to be

the shafts, pumping stations, and

one of the world’s largest and

underground infrastructure to

lowest-cost zinc producers,

prepare the mine for the restarting of

while also producing signifi-

commercial production.

cant quantities of copper,

Once in full operation, Kipushi will be

silver and germanium.

the world’s highest-grade major zinc

We remain involved in

mine, with an estimated 10.2 million

detailed discussions with

tonnes of measured and indicated

potential strategic partners

mineral resources grading of 34.9%

and investors relating to the

zinc. A two-year construction period is

company and our projects,

part of the mine redevelopment plan

including Kipushi,” says Robert

to reach the projected steady-state

Friedland, executive chairman,

production of 530 000 tonnes of zinc

Ivanhoe Mines.

concentrate per annum.

Kipushi Corporation has upgraded

The rebirth of the Copperbelt legend

the operating shafts, winders and

has an estimated 10.2 million tonnes of

underground infrastructure at the

TOP A Y-junction on the 1 200 m level at the Kipushi Zinc-Copper Project

zinc, which is more than twice as high

Cascade section of the mine. The in-

ABOVE Copper stainings

as the measured and indicated miner-

frastructure will serve as an alternate

al resources of the world’s next-highest-

personnel and material shaft and as a

grade zinc project, according to Wood

second egress route from the mine. The

Gécamines, and the people of the

Mackenzie, an international industry

main production shaft for the mine is

Kipushi area to return the mine to pro-

research and consulting group.

in the process of being upgraded and

duction and start writing the next chap-

recommissioned.

ter of Kipushi’s long and meaningful

Now that dewatering is complete, the company is poised to do confirmatory drilling of historic resources

Besides the new high-volume venti-

history. In the meantime, we welcome

lation fan installed at Shaft 4, the main

international investors and mining ana-

personnel and material winder has

lysts to see, first-hand, the excellent pro-

been upgraded and modernised as

gress our team has made in upgrading

well. The rock-hoist-

the mine’s underground infrastructure

ing winder is being

and to experience an exceptionally

upgraded and will

rare opportunity to inspect a deposit

have a potential

that is 35% zinc,” says Friedland.

hoisting capacity

The critical path for the redevelop-

of 1.8 million tonnes

ment of the mine runs through the

per year. The up-

upgrading of the Shaft 5 rock-hoisting

grade and instal-

winder, as well as the recommissioning

lation is expected

of the main pumping station at Shaft 5,

to be complete

the underground crusher at the bottom

and operational by

of Shaft 5, the Shaft 5 rock load-out

late 2017.

facilities, and the restoration of the

“We look for-

main haulage way on the 1 150 m level

ward to working

between the Big Zinc access decline

with our partner,

and Shaft 5.

In sid e M in in g 0 1 | 2017

MINING IN AFRICA

Maniema Gold acquisition in progress Vector Resources recently announced its plans to acquire a 70% stake in the Maniema Gold Project in the DRC. The company is now finalising its US$1 650 000 capital raising.

he Maniema Project – locat-

target for Kabotshome of between 7.0 Mt

ed about 260 km south-west of

at a grade of 1.9 g/t Au (423 000 ounces)

Bukavu and 160 km east of Kindu –

and 7.5 Mt at a grade of 2.5 g/t Au

comprises seven granted explora-

(603 000 ounces). The exploration

Main target areas identified by soil sampling on the Maniema Project

tion licences covering an area of 500 km

target has been based on previous

Capital-raising

and contains five main prospects, namely

exploration work, geological modelling

Vector Resources entered into an

Kabotshome, Mbutu, Mitunda, Mbala,

and mineralisation work completed. The

agreement with African Royalty Com-

and Tubambo. Of the five prospects, Ka-

exploration target’s quantity and grade

pany (ARC) to acquire a 70% interest in

botshome is the most advanced.

are conceptual in nature. There has been

the Maniema Gold Project. Under the

insufficient verification of mineralised

agreement, Vector Resources agreed

alluvial gold mine in the 1960s, operated

estimates and exploration results to outline

to acquire ARC’s rights under an agree-

by Belgians. The mine is still active and

a JORC 2012-compliant mineral resource.

ment that ARC has entered into with WB

worked by artisanal miners. All 17 holes

“The exploration of the Maniema Gold

drilled along the main target revealed

Project includes geophysics, stream sedi-

The Kaboshome Project used to be an

Kasai Investments Congo. By November 2016, the company

gold mineralisation along the Kabot-

ment sampling, soil geochemistry, trench-

managed to secure US$300 000 of inter-

shome structure. The mineralisation was

ing and drilling. Five different prospects

im debt funding. It soon started with a

generally 15 m to 25 m wide, with a

were identified from the soil sampling, and

non-renounceable pro-rata entitlement

grade range of 1.5 g/t to 2.5 g/t Au.

four of the samples were then trenched to

issue of one new share for every one

better define drill targets. The drilling was

share held by eligible shareholders at a

grades were reported where the main

carried out on the Kabotshome, Mitunda

price of $0.001 per share, in an effort to

shear zone identified at the surface inter-

and Mbutu prospects,” says Younds.

raise $1.35 million.

The company revealed that the best

sects the sediments, which reported 20.25 m at 2.5 g/t Au (from 319 m), including 8 m at 4.03 g/t Au, and 21.7 m at 3.58 g/t Au (from 354 m), including 5.7 m at 8.74 g/t Au down to 300 m below surface. “Nearly all intersections reported a high-

Item of expenditure

Amount in US$

er-grade, narrower interval of between

Cash consideration due on completion of acquisition

300 000

5 m and 7 m, with grades of 5 g/t Au to

JORC code resource definition drilling programme

500 000

8g/t Au and up to 118.5 g/t Au,” says Si-

Trenching, sampling and surveying

200 000

mon Younds, CEO, Vector Resources.

Assaying and testwork

300 000

Transaction and capital-raising costs

100 000

Corporate and administrative costs and working capital

250 000

Exploration target The company’s technical consultants have determined an initial exploration

Table 1 Capital required for the Maniema Gold Project

Ins i de Mi n i n g 0 1 | 2 0 1 7

Total

1 650 000

MINING IN AFRICA

New scrubber for Debmarine

A new Tenova dynamic scrubber will be installed on a deep-water diamond exploration and sampling vessel, as a wet dust-extraction system. The MV SS Nujoma will be operated by Debmarine Namibia off the coast of Namibia and the west coast of South Africa.

he scrubber will collect dust

in the 1 µm to 2 µm range. The smallest

extracted from the air in a slurry,

dynamic scrubber can handle 0.2 m3/s,

before discharging it into on-

while twin arrangements of the largest

board sumps that utilise seawater.

scrubber handle up to 65 m3/s.

The air vented to the atmosphere will

Previously known as Bateman

The MV SS Nujoma entering Cape Town before fitting

associated with De Beers Marine since the 1990s,” says Tomlin. The company’s scope of work covers

contain less than 30 mg/Nm2, well within

Engineered Technologies (BET), prior to

environmental regulations. In the diamond

the acquisition of the Bateman Group

design, supply, manufacture and

processing industry, wet dust-collection

by Tenova in 2012, Takraf Africa supplied

delivery, as well as technical assistance

systems are the preferred means of

dynamic scrubbers as well as other

during installation and commissioning

achieving low dust emission levels to

equipment for most of De Beers Marine’s

on the quayside and at sea, where hot

protect both operators and machinery.

sea mining vessels. These include the

commissioning will take place. De Beers

“Tenova Dynamic Scrubbers are simple

deep-sea mining vessels MV Debmar

Marine placed the order for supply of the

to operate and enable low dust emissions

Pacific, MV Debmar Atlantic and MV

scrubber following successful completion

to be achieved with relatively low capital

Peace in Africa.

of the initial design study phase awarded

and operational costs,” says Jimmy Tomlin,

“We highly value such repeat orders as

to ADP Consulting. The 4.5 m3/sec

manager: Air Environmental Control,

they are testimony to both the superior

scrubber was ordered in November 2015

Takraf Africa.

performance of Takraf Africa’s technology

and will be installed by ADP Consulting

as well as our commitment to supporting

on the sampling vessel, which is under

collection of medium to heavy dust loads

our products over their complete life

construction at the South African port of

with an efficiency of 99% for particles

cycles. We are proud to have been

Cape Town.

The scrubbers are used for general dust

In sid e M in in g 0 1 | 2017

Chamber Of Mines

Mining Charter draft concerns The Chamber of Mines South Africa raised some concerns after the revised version of the Draft Reviewed Mining Charter was released in late 2016. Its implementation in its current form is ill-considered and holds dire consequences for industry and the economy, says the body.

ensures the transformation journey we have embarked upon does not lose its momentum. The Chamber considers the process to arrive at this Draft Reviewed Mining Charter to have been seriously flawed. Following the publication of the first Draft Reviewed Mining Charter in April 2016, the Chamber has only been

he revised version of the Draft

industry and the entire South African

invited to consult with the DMR on

Reviewed Mining Charter was

economy at a time when both are fac-

two occasions, despite its willingness

submitted to Parliament by

ing significant challenges,â&#x20AC;? says Roger

to engage.

Mosa Mabusa, deputy director

Baxter, CEO, Chamber of Mines.

The Chamber would have preferred

general, Department of Mineral Re-

The Chamber has been

a situation where the stakeholders

sources (DMR).

at pains to point out to

in the Mining Industry Growth and

the DMR that the in-

Development Employment Task

dustry is in dire straits. In

Team had the opportunity to engage

â&#x20AC;&#x153;The chamber is deeply concerned that the Draft Reviewed Mining Charter contains ill-considered and/or unachievable targets, and that its implementation in its current form will have dire consequences for the mining

this crisis situation, what is needed is a charter that promotes investment by providing a steadily progressive

Roger Baxter, CEO, Chamber of Mines South Africa

transformation tool that simultaneously

Ins i de Mi n i n g 0 1 | 2 0 1 7

and predictable

extensively in the development of the stakeholder-agreed Mining Charter, as was the case in 2002 and 2010 for the first two versions of the charter. In terms of the substance of the Draft Reviewed Mining Charter presented by Mabuza, it has become clear that the DMR has not considered and/or not

Chamber Of Mines

Concerns Concerns raised by the Chamber of Mines relating to the Draft Reviewed Mining Charter that the Department of Mineral Resources has not taken on board concern:

The DMR has pursued the proposal that mining companies must contribute a proportion of revenues to a mining transformation and development agency (MTDA). Simply stated, this proposal is yet another “royalty” tax equivalent that the DMR intends to impose on an already struggling industry, which made a loss of some R37 billion in 2015. This is the most regressive form of taxation. For this reason, Treasury elected for an EBIT-based royalty rather than a revenue-based one. The Chamber proposed a 2% of net profit after tax contribution to community expenditure and the need for government to use the existing royalties paid by mining companies to government to supplement community development initiatives.

Chamber is concerned about the establishment of 2 aTheMTDA as proposed by the DMR, which parties have not discussed in any degree of detail. The Chamber is concerned about its purpose, cost and oversight.

The Draft Reviewed Mining Charter requires that a portion of the industry’s skills development commitments should be paid to the MTDA. This will take away much-needed funding for skills programmes and tertiary education currently undertaken by the companies and will place these funds directly with another government agency whose mandate is unknown.

The DMR continues to insist that multinational companies supplying goods and services to the mining industry should pay 1% of turnover generated from local mining companies to the new MTDA. This doubles the target set in the 2010 Mining Charter. The Chamber is of the view that this is simply an additional tax that multinational companies will pass on to local mining companies in the form of higher prices, rendering the South African mining industry less competitive than it already is.

Further, the DMR has substantially increased the targets relating to the appointment of historically disadvantaged South Africans in companies, and has at the same time changed the definition. The new targets may be desirable, but some aspects are – in the industry’s view – currently unachievable. The industry on the whole achieved the employment equity targets of the 2010 Charter and is not opposed to increasing the targets; however, the targets have to be based on what is realistically achievable.

included the Chamber’s submissions, ob-

respect of the “continuing consequenc-

serious viability crisis currently being faced

jections and recommendations.

es” component is likely. Regrettably,

by the South African mining sector, the

while the high-level meetings between

DMR has not offered or displayed any

of all the DMR’s proposals, combined

the industry and the DMR, including the

interest in assisting the industry through

with existing corporate taxes and royal-

minister, appeared to have been able

this crisis. The only area where the DMR

ties, skills development levies and more,

to reach a common understanding on

has been visible was through the ‘Lead-

would materially affect the viability of an

the way forward, the outcomes have not

ers’ Declaration – Mining Industry Com-

industry already in crisis.”

progressed beyond verbal agreements,

mitment to Save Jobs and Ameliorate the

and the last meeting between the DMR

Impact of Job Losses’, where the depart-

the DDG indicated that consultation with

and the Chamber’s principals took place

ment’s focus was solely on the measure of

the industry in respect of the ownership

in July 2016. This is despite the Chamber

preventing the industry from restructuring.

element of the Charter has been fruitful,

providing detailed inputs on the issue in

The DMR has not pursued the other meas-

and that a withdrawal of the Chamber’s

September, as had been requested. The

ures explored, such as reducing cost pres-

application for a declaratory order in

Chamber further notes that, despite the

sures or developing the markets.

Baxter notes: “The cumulative effect

The Chamber notes with concern that

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Legislation

Successfully navigating BBBEE codes

his is because BBBEE compliance and implementation has evolved into an extremely detail-oriented activity.

The skills required are highly analytical, requiring a combination of an understanding of law, human resources and an ability to develop a practical strategy. “Yet SMEs with a turnover of between R10 million and R50 million per annum are often surprised to find they can implement a strategy at negligible cost, which improves their scorecard rating and puts them in a position to tender for business that was previously out of their grasp,” explains Yolandie Botha, director, Innovative BEE Solutions. The average SME will not be able to afford the skills necessary to implement a BBBEE strategy to their full advantage. “The ability to simplify the intricate detail of the BBBEE legislation into something that can be implemented into a business is a critical strength that a company such as ours possesses,” continues Botha.

Categorising companies The first consultation with a client usually involves an evaluation of the client company in order to determine the current status and degree of its BBBEE participation. “If a company’s annual turnover is less than R50 million, it becomes relatively easy to improve its rating even in the current year. Companies turning over more than R50 million will need a bit more work and usually require some restructuring to deliver a scorecard increase in the following

Yolandie Botha, director, Innovative BEE Solutions

Ins i de Mi n i n g 0 1 | 2 0 1 7

Today’s typical small to medium-sized enterprise (SME) tends to regard BroadBased Black Economic Empowerment (BBBEE) together with labour regulations as an unmitigated nuisance. A common response is either to pretend the codes don’t exist or to treat BBBEE as just another tax.

year,” adds Botha. The updated BBBEE codes came into effect from May 2015. The codes’ categories for compliance have been condensed from seven to five categories, three of which are regarded as compulsory and must be adhered to in order to be compliant. Two of these enable a company to earn tax rebates and points by redirecting mandatory expenditure. Botha identifies the three compulsory categories as: • ownership • skills development • enterprise and supplier development.

Legislation The BBBEE levels range from one

is calculated according to the Economic

but unless that contractor is a registered

(the highest) down to eight or

Active Population (EAP) targets. In order

company, they cannot claim the score-

non-compliance.

to score points on your BBBEE scorecard, it

card points,” adds Botha.

would be advisable to contact a profesThe revised codes have much stricter rules when it comes to the scoring process and

sional BBBEE consultant. In addition, companies can claim back

“Professional consultants put structures in place to assist with suppliers and enterprises in order for the clients to earn

harsher implications for business owners.

a portion of the 1% skills development levy

maximum points. There are also mecha-

The revision has not yet affected many

payable, if they pay towards external train-

nisms by which a network is developed,

companies, as it will only apply to cur-

ing, by submitting

rent certificate verifications. “The revised

a workplace skills

Codes of Good Practice will really only

plan to the SETA.

affect those companies with turnovers

An additional

that exceed R10 million, and especially

means of inex-

those with a turnover of more than R50

pensively improv-

million, says Botha.”

ing one’s BBBEE

How to benefit

rating is through Enterprise Devel-

“An additional means of inexpensively improving one’s BBBEE rating is through enterprise development.”

and each party provides services to the other for which no money passes hands, but it earns points for code scorecard purposes,” says Botha. BBBEE consultants should attend

She outlines two simple means by which

opment. From her

companies can financially benefit from

experiences, Botha surmises that the aver-

to all legal formalities to ensure clients’

the new codes. “An employer can reg-

age company is already doing something

contractors are BBBEE compliant. These

ister a learnership, in which case the

in this regard and incurring expense.

are listed in the codes and qualify for

employer can receive up to R40 000 per

“However, they often don’t have a

rand value. The list includes interest-free

learner on tax rebates for an annual and

paper trail or don’t record their activities

loans and prepayments for other services,

completion allowance. This rebate is not

and, as a result, they fail to get the rele-

bartering of goods such as protective

restricted to any racial or age group;

vant code scorecard points. For instance,

clothing and equipment, and in-house

however, the racial factor is critical and

companies may appoint a contractor,

skills development.

PART OF THE MINING PROCESS.

BMG doesn’t merely deliver superior quality engineering components to the mining industry. We know that to truly deliver, to truly provide optimum service for our customers’ needs, our solutions need to be accompanied by both insight and foresight. Insight into the technical requirements of your operating process as well as your budgetary parameters, gained through personal, direct and thorough consultation. Foresight into how our technical expertise, on-site maintenance plans, custom design capabilities and training can all be applied to further maximize your production efficiencies. It is this commitment that has driven BMG to become a powerful industry leader. Parts for every process. Part of yours.

For more information contact your nearest BMG branch.

BEARINGS • SEALS • POWER TRANSMISSION • DRIVES & MOTORS • MATERIALS HANDLING • FASTENERS & TOOLS HYDRAULICS • PNEUMATICS • FILTRATION • LUBRICATION • VALVES • TECHNICAL RESOURCES • FIELD SERVICES

Mechanised Machinery

Improving underground

safety

The need for safer underground environments in coal mines has urged researchers to find innovative methods to minimise the presence of methane gas and coal dust. Coaltech’s ingenious Prevention of Methane Ignitions project makes use of air amplifiers to boost the safety of underground operations. By Mientjie Kleinhans

he project to reduce the risk of methane gas ignitions and coal dust exposure risk in underground coal mines commenced four years ago, having initially started as a process to determine

the contributing factors for methane gas ignitions in a continuous miner heading. A year ago, the focus of the project shifted to finding a solution to eliminate the occurrence of methane gas ignitions while continuous miners are cutting and determining the role of airborne coal dust particles in the appearance of ignitions. The project has now reached a stage where the Coaltech team will be testing air amplifiers on continuous miners while producing coal. The development and evaluation of these air amplifiers will continue for at least the next year. The use of air amplifiers is not a new concept to mining – having been used in gold mines and platinum mines before, though for different applications. Using these air amplifiers with the aid of compressed air on continuous miners has never been done in the coal mining industry before. Cor Meyer, project leader, Coaltech, explains that the original air amplifiers, as used in the hard-rock mines, were redesigned to work specifically on the continuous miners. “Once the research is concluded and it can be proved that

these air amplifiers effectively dilute and remove the methane-/dust-laden air from the immediate cutting environment, it will be the first of its kind to succeed in underground coal mines,” says Meyer. The air amplifiers are mounted at the front of the machine

Ins i de Mi n i n g 0 1 | 2 0 1 7

Mechanised Machinery

1 A side view of the air amplifiers being tested 2 The air amplifiers being mounted on the machine in the workshop

Gas monitoring equipment The project initially started off with Coaltech realising that methane monitors are inappropriately positioned on the continuous miners. As methane tends to accumulate underneath the cutting drum, the methane monitors were placed as close as practically possible to these areas. Through the use of computational fluid dynamics (CFD), it was possible to identify the optimal monitoring position on the machines. Through the better positioning of these monitors, more reliable results are possible and management is better equipped to take steps to prevent methane-related incidents.

“Discovering that the monitoring equipment should be moved closer to the front of the machine made us realise that methane levels are likely higher than we initially estimated, and that we need better ventilation in this area as well. Through careful consideration and the evaluation of the shortfalls of current on-board ventilation systems, the idea of using air amplifiers on continuous miners was conceived,” says Meyer.

Air amplifiers The air amplifiers redesigned for use on continuous miners combine the use of compressed air with water. The compressed air atomises the water droplets, and the combination of air and water is then directed on to the coal face. The fine water droplets address the airborne coal dust particles, while the compressed air addresses the methane gas that is released from the face during the cutting process. “Through the air amplifiers, we tend to use less water than with the traditional water spray systems installed on the continuous miner cutter head. Our aim is to eventually move away from using clean water in these systems to using solely process water,” explains Meyer. The surface tests done so far reveal that only small amounts of air and water are needed to create the required flow of air and mist on to the coal face. As a comparison, the average sprayfan system on a continuous miner uses 110 ℓ of water per minute, while the air amplifiers fitted on the machine only require an estimated 5 ℓ of water per minute, through each unit. “It might be even less; we still need to conduct more research to determine the exact water and air consumption quantities. It is impossible to compare the results from the gold and platinum mines to the results that we expect from the coal mines, as they present vastly different conditions, and methane and dust concentrations,” says Meyer.

He adds that the air amplifiers operate on the Coandă effect, which is the tendency of a fluid jet to stay attached to a convex surface. However, more research needs to be done on these specific units to identify how much air is actually generated when water is added to the equation, as the water droplets change the density and characteristics of the air. “We need to establish the energy usage of the compressed air and water, and the effect on air distribution through real-time underground observations,” he points out. As a starting point, the trial machine will be equipped with four air amplifiers directed at varying angles on top of the continuous miner, in an attempt to cover most of the cutting face area. The water and air combination will be sprayed on to the coal face and the on-board scrubber system will assist in removing the contaminated air from the cutting area.

Challenges Many months’ worth of research brought with it numerous challenges. “Among the biggest challenges we face now are the safety risks we need to address regarding the underground

In sid e M in in g 0 1 | 2017

8th ANNuAL

WOMEN IN MINING

CPD CREDITS 3 (1 PER DAY)

-Moving From The Integration To The Development Of Women In Mining Date: 22, 23 & 24 February 2017

Venue: Gallagher Estate, Midrand

INTERNATIONAL PERSPECTIVE cynthia carroll Chairperson VEDANTA RESOuRCES HOLDING

Wendy Treasure Director of Academia and Research INTERNATIONAL WOMEN IN MINING (IWIM)

Monica Ospina Founder and Director O TRADE Member INTERNATIONAL WOMEN IN MINING (IWIM)

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

Duduzile Kunene Regional Manager WESTERN CAPE DEPARTMENT OF MINERAL RESOuRCES (DMR)

Beauty Mazibuko Head of Business Services ANGLO THERMAL

Sarah Luthuli Vice-President: Corporate Affairs and Human Capital FOSKOR (PTY) LTD

Nosiphiwo Nyamane Manager: Mineralogy MINTEK

Lebogang Ramphele Group Enterprise Development Practitioner PETRA DIAMONDS

Farana Boodhram Mining Director AVITA MINING

Avheani Rabumbulu Mine Planning Engineer THARISA MINERALS Nozipho Zitha Transformation Superintendent PALABORA MINING COMPANY

Sisiwe Mthethwa Manager Training & Development PALABORA COPPER (PTY) LIMITED nondumiso nonkululeko Radebe Social Compliance & Sustainability LAFARGE MINING

Olebogeng Sentsho Head of Operations YEABO MINING Dr Lilita A Marques Human Resource Development Manager NAMDEB DIAMOND CORPORATION

SKiLLS-DRiVEn wORKShOPS FOcUSinG On wOMEn in MininG ADDRESSING THE MINE HEALTH AND SAFETY ACT WITH SPECIAL FOCuS ON WOMEN Adv Johann Raubenheimer Risk Management Consultant HOGAN LOVELLS

ADDRESSING THE LONG TERM EFFECTS OF NEGATIVE RESILIENCE nonhlanhla Sibanda - Moyo Gender and Women’s Rights Specialist CENTRE FOR THE STuDY OF VIOLENCE AND RECONCILIATION

KEY STRATEGIES TO BE DISCuSSED: • • • •

Advancing the mining industry by investing in the research, development and training of women Understanding the current state of the mining industry in order to make a positive contribution Becoming an SMME supplier by looking at current opportunities Empowering women in mining to lead in a man’s world

• • •

Encouraging women to report sexual violence with accuracy and in turn provide a supportive environment Discussing women’s physical abilities and overcoming common challenges Evaluating your Social Labour Plans and needs analysis of the community

CONFERENCE HIGHLIGHTS Join iTc at the end of Day 1 for a Speed networking session

Join ITC at the end of Day 2 for an interactive image and makeover session

Feedback & recommendations will be forwarded to key authorities after the conference

CPD VALIDATED ITC is a BY: proud

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

ITC IS ETDP & MICT SETA ACCREDITED & A LEVEL 1 B-BBEE COMPANY

member of:

Mechanised Machinery

3 T he air amplifiers need to be boxed in during the test phase for protection purposes 4 During the test phase of the air amplifiers 5 The compressor is placed more towards the back of the machine

use of compressed air. Another challenge is to install compressors on the continuous miners. Because this is a new concept, and ready-made compressors built for this purpose are not yet available, the developing costs of these compressors prove to be somewhat expensive. As the project progresses and custom-made compressors become more readily available, the total installation costs, and potentially the energy requirements, will be reduced. As technology advances, these compressor units and air amplifiers will become smaller, more effective and more energy efficient,” explains Meyer.

Balancing the compressed airflow requirements and water usage is an additional challenge Coaltech is working on at the moment. Meyer adds that the first trial compressor unit is electric driven, which, in itself, presents great challenges in terms of safety, legalities and approvals. “Going forward, we want to go hydraulic, but that will very much depend on the space availability on the continuous miners, the capacity of the hydraulic motors, and the resultant size of the compressor units.”

Benefits Production rates in South African coal mines have increased over the past years, and methane gas concentrations and airborne coal dust levels have increased as a result. “Ventilation systems that were developed 20 years ago are not as effective anymore, and it is time for the industry to become innovative again and develop new systems. Now is the perfect time to introduce the concept of these air amplifiers to ensure a safer and healthier working environment,” Meyer opines. The end result will be well worth all the months of research and hard work,

as there will be many benefits, including clean, clearer and safer environments for workers. Production will also increase, as continuous miner downtime will decrease owing to a reduction in methane-induced trips. Meyer explains: “At a coal mine with high levels of methane gas, continuous miners can experience as many as 10 or 12 methane trips per shift. This means the machine has to be pulled out of the face area, and the methane has to be cleared before the machine can return to the face and continue cutting. This procedure can take up to 30 minutes or longer before the machine can operate again. If the amount of methane can be diluted and controlled effectively, methane trips should be eliminated, leading to increased productivity.”

Future plans The team plans to run more tests in another mine with high methane levels by equipping an additional continuous miner with an air amplifier. The machine will run for about two or three months and the

team will, hopefully, get the desired results. This will still only be the test phase. The project is estimated to run until April 2018. The design and development, by the various OEMs involved in the project, will only start thereafter. “The vision is to have the air amplifier system installed on the machine before it is delivered to the mine. This will mean redesigning and modifying the mining machinery. The air amplifier system will be custom-made according to the mine’s specific requirements. The design will take certain aspects into consideration, such as mining conditions, the size and capacity of the continuous miners, methane release rates and air requirements for the coal face area,” concludes Meyer.

In sid e M in in g 0 1 | 2017

Laboratory Analysis

Every mine’s bedrock

for sustainability Analytical and Calibration Services (ACS), a department within the element analysis in liquid, solid and South African Nuclear Energy Corporation (Necsa), assists mines that gaseous samples. need analytical chemistry and radiological expertise to assist with the With vast expertise in assessment, monitoring and control of site risk and compliance, analytical chemistry, ACS provides advice on the most environmental impact studies, and raw material, production appropriate analysis for a specific parameter, and end-product analysis and/or certification. purpose and regularly adapts and develops new methods in support

of changing needs. This is a specific requirement for supporting research CS has evolved significantly

continued world-class support to

and development for Necsa and is,

since the 1960s, when

Necsa’s growing diversity, as well as

therefore, a core capability of the

it was made up of a

the South and Southern African mining

laboratory. A large number of the

number of separate

industry facing similar compliance

chemical and environmental analyses

requirements.

are accredited by South African

specialised laboratories, providing a unique portfolio of services. In 2007,

What makes ACS unique is that the

requiring compliance with a myriad

company has developed efficient and

of ever-changing national and

cost-effective mechanisms to suit the

international legislative and standards

client of the “now”.

requirements, Necsa started merging

these complementing capabilities

Analytical chemistry

into a single department – ACS. The

Its analytical chemistry capabilities

predominant aim was to provide

include, among others, trace

Ins i de Mi n i n g 0 1 | 2 0 1 7

“A large number of Necsa's chemical and environmental analyses are accredited by Sanas.”

Laboratory Analysis Necsa offers a wide variety of services

National Accreditation System (SANAS) (Testing Laboratory T0168) and the processes for working with natural and enriched uranium are also licensed by the National Nuclear Regulator (NNR) (Nuclear Installation Licence 40). Necsa and the mines have to comply with similar legislation with regards to safety, health and environmental protection, as well as compliance with raw materials and product specifications. Many consultants make use of the analytical chemistry capabilities to perform a wide variety of analyses with accurate results, even at ultra trace levels, for product certification, drinking water (against SANS 241), surface- and groundwater, gas monitoring, environmental, and

(Testing Laboratory T0111). As for the

ACS provides radiological protection

safety standards. The department

analytical chemistry laboratory, all

support services for:

also supports personnel monitoring for

processes for working with natural

• planning and execution of baseline

uranium and other contaminants, such

and artificial radionuclide materials

as heavy metals, in urine.

are licensed by the NNR (Nuclear Installation License 37).

RadioAnalysis

characterisation surveys to assist in

Radioanalytical methods are

The NNR is always very stringent

designed to determine the diverse

when it comes to compliance

radionuclides in the uranium and

requirements and, therefore, to assist

thorium decay series present in various

the mining community to adhere to

types of naturally occurring radioactive

these regulatory controls, an extensive range of Sanasaccredited analysis methods are offered

studies for prospecting • performing radiological

materials (NORMs). Mining activities may enhance radionuclides to such levels that they may pose a potential hazard. The radioanalytical methods have the required sensitivity to produce results that will allow for the proper assessment of the radiological impact of mining operations on workers, the public and the environment.

Radiological protection support Mining companies will be pleased to know that

the remediation of former NORMcontaminated mine properties • assisting with the application for authorisation by the NNR • developing radiation protection programmes • planning and executing environmental impact assessments • assessing the integrity of sealed sources used in industry.

Radiological instrument calibration The radiation dosimetry metrology laboratory aims to ensure the radiological instruments used are calibrated and accurate, to ensure a safe environment for workers and the public. ACS’s phenomenal expertise in radiological instrument calibration services provides calibration of: • personal dosimeters • portable radiation and contamination monitors (and survey meters) • installed radiation and contamination monitors • radioactive airborne particulate samplers and monitors (including flowrate calibration) and radon monitors. Most of the calibration methods are accredited by Sanas

In sid e M in in g 0 1 | 2017

Laboratory Analysis (Calibration Laboratory 1203) and these laboratories are authorised by the Department of Health to work with sealed sources.

Nuclear forensics Another wing of ACS, Nuclear Forensics Services, works in close collaboration with law enforcement agencies, both locally and internationally, to identify any illicit nuclear materials, tracing them back to the source, so as to maintain a safe and secure environment at all times. This laboratory performs analyses on nuclear materials to determine from which geological deposits they originate and provides inputs to the South African Database of Nuclear Materials.

Proudly South African Necsa promotes the nuclear science, technology and engineering expertise of South Africa and improves the public understanding of these through regular communications at various forums and outreach programmes in the community. NTP Radioisotopes SOC Ltd, a subsidiary of Necsa, is one of the top suppliers of cancer treating medical radioisotopes in the world. Pelchem SOC Ltd, another subsidiary, supplies fluorine and fluorinebased products used for the manufacturing of a variety of products, such as painkillers and

specialised laboratories Necsa’s Analytical and Calibration Services Department hosts a number of specialised laboratories that can assist mines with the monitoring and control of: • Site risk and compliance assessment • Environmental impact studies • Raw materials and production parameters • End-product quality and certification

electronic components, to national and international customers. Necsa is earning valuable foreign exchange for South Africa and ACS laboratories play a crucial role for Necsa and its subsidiaries. This proudly South African company is located on the Pelindaba site, only 30 km west of Pretoria, and within easy reach for most South African mines. Pelindaba, from the Zulu word for “done talking”, is an ecological reserve maintained and protected by Necsa, as part of preserving the environment for future generations. Who would have thought that amid lush green trees, with the odd rooibok and wild monkeys, lies a centre of excellence so essential to South Africa and the needs of every mine?

www.necsa.co.za labservices@necsa.co.za

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Laboratory Analysis

Tips for top lab results Getting the best results from a commercial laboratory is crucial for mining companies, and a little advice from an industry expert is always welcome. David Long* answers a few questions that will assist a mine on how to use a commercial laboratory effectively A commercial laboratory is a facility that tests materials (solids, sludges, liquids, gas, etc.) for many reasons, including to assure product integrity, quality, safety and efficacy. Mines benefit from getting the best results from a lab.

Many businesses are using foreign expertise. What is the biggest difference between local and foreign expertise or service? Some South African laboratories are 100% on par with international counterparts in terms of both

How do you know if a lab is suitable for your business? Be clear about what information is required from the testing campaign and know that labs specialise

in specific types of testing, so it is best to find the most

equipment and technical expertise. As a leading mining

appropriate laboratory for the requirements. Scheduling

economy globally, South Africa has been instrumental in

a consultation with the laboratory to find out more about

pioneering some of the methods used worldwide for the

its areas of expertise and capabilities, as well as doing

exploration and operation of mining interests and, as such,

independent research go a long way towards finding the

there are many leading experts operating in South Africa.

best laboratory to service specific needs. This will prevent time and money wasted on performing tests that yield little

useful information. In addition, some labs may not be able How do you guarantee optimal results?

to perform the specific analysis required and may opt to use

The phrase “garbage in, garbage out” is most

a subcontractor. When planning on sending a sample to

appropriate in the case of scientific testing.

more than one lab to compare results, it is important to know

Manage samples with care in both collection

if the work will be subcontracted to avoid sending the work

and transportation to ensure the most accurate results.

to multiple labs who may use the same subcontractor. It’s

Engage with laboratories to ascertain the requirements for

also worth confirming whether a standard or non-standard

maintaining sample integrity, such as specific handling and

method will be used for the analysis.

lifespan. For example, water samples are perishable and may need special handling en route to the laboratory. Hedge against sample discrepancies between labs by understanding testing methodologies employed.Equipment and process variations between laboratories do impact test results. A lab only able to analyse samples in liquid form may obtain results different

Is waste potentially profitable? Sludges and other waste materials discarded in the production process could be repurposed into saleable products. Testing and characterisation of waste materials to

to tests done on solid samples. This becomes pertinent

determine chemistry and mineralogy could identify

when suppliers price outputs at a specific grade and the

additional income streams for waste directed to landfill;

buyer disputes grading based on differing independent

for example, pyrolysis of rubber and car tyres produces

test results. Understanding these drivers could go a long

a form of carbon black, which can be used as pigments

way in anticipating and resolving price disputes related

and fillers as well as petroleum that can be used as an

to product grading.

alternate fuel.

*David Long is the co-founder of Sci-Ba.

In sid e M in in g 0 1 | 2017

Transport

Largest hauler launched Southern Africa will finally be able to experience Volvo’s largest ADT, which was launched in Germany in 2016. The Volvo A60H is the largest articulated hauler of its kind in the world.

Another first for Babcock in 2017 will be the Generation 10 TA300 and TA400 articulated dump trucks from Terex Trucks. Erik Lundberg, business manager: subSaharan Africa, Terex Trucks, says that the Generation 10 ADTs are the first new Terex Trucks products to be launched by the company since Volvo CE acquired the Terex Trucks brand in June 2014, and

he A60H’s higher payload

Babcock already pre-sold three Volvo

Babcock’s subsequent appointment as

represents a 40% increase on

A60H articulated haulers, as well as

the official distributor in Southern Africa

Volvo’s A40 models, significantly

one Volvo EC950E excavator to Burgh

of these powerful articulated haulers and

lowering the cost-per-tonne ratio

Plant Hire, a long-standing customer, at

reliable rigid haulers. Terex Trucks is renowned for delivering

for hauler customers, while its stability,

the Bauma 2016 exhibition in Germany.

comfort and high hauling speeds are

Stanley van der Burgh, CEO and owner

a robust performance in the steepest,

ensured by the matched drivetrain,

of Burgh Plant Hire, owns a fleet of

deepest mines and largest quarries

automatic drive combinations, all-

more than 100 Volvo machines for his

around the world while simultaneously

terrain bogie, hydromechanical

company’s coal mining operations

providing durability, comfort and

steering and active suspension, further

– the majority of them articulated

efficiency. The Generation 10 TA300 and

optimising production and minimising

haulers – so he has full confidence in

TA400 reflect Terex Trucks’ reinvigorated

operational costs.

the new model.

attitude towards performance and

The first A60Hs are expected to reach

Terex Trucks

quality, and have been designed to

South Africa’s shores by March and

Volvo A45G articulated hauler

will be launched into the Southern

Babcock will also be bringing the

enhance the operational efficiency and

African market by May, together with

groundbreaking Volvo A45G articulated

effectiveness of the ADTs on the toughest

the new Volvo EC950E – a 90 t crawler

hauler to Southern African shores this

job sites. The TA400 ADT is the largest of

excavator that combines power and

year. Designed for heavy hauling

the company’s new Generation 10 ADTs

stability to handle a higher capacity in

in severe off-road operations, this

and excels in large-scale construction

the toughest applications. “The A60H

“ultimate hauler” delivers unbeatable

projects, quarries and mine sites alike.

is ideal for hard-rock mining, coal

off-road performance in its class and

Babcock is confident that 2017 will

mining, general mining and big quarry

an increase in payload of two tonnes

be an exciting year for the company’s

applications, and the EC950E has been

on the A40. Volvo is the world’s leading

designed to load the massive A60H,

manufacturer of articulated haulers and

so they work hand in hand,” says

the new A45G displays all the hallmarks

David Vaughan, managing director,

of a Volvo articulated hauler, including

Babcock Equipment.

strength, durability and fuel efficiency.

Ins i de Mi n i n g 0 1 | 2 0 1 7

improve customer productivity and

The 90 t Volvo EC950E crawler excavator combines power and stability

Transport Equipment Division. “With indications of recovering commodity prices, our customers have a positive outlook for 2017,” says Vaughan. Babcock is the sole regional distribution and service agent for Volvo Construction

RIGHT The Generation 10 TA300 and TA400 articulated dump trucks from Terex Trucks will be another first for Babcock BOTTOM RIGHT Volvo’s EC950E crawler excavator pairs well with the new articulated hauler

Equipment, Terex Trucks, Tadano and Sennebogen cranes, Winget concrete

turnaround time, and the response from

handling equipment, and SDLG

our customers has been exceptionally

construction equipment.

positive,” says Vaughan.

“The mining sector remains an integral

“The world-class facility is well stocked

market for Babcock, particularly

with inventory lines, so we very seldom

customers operating in the coal fields of

have to wait for parts. The sales team is

Middelburg,” says Vaughan, who was

always willing to assist us at the drop of

previously sales director at Babcock

a hat,” says Mark Johnstone, managing

Equipment, and has been with the

director, Atlantis Mining, an open-pit

company since 2005.

coal mining subcontracting company.

Sales, parts and service

the demand for larger construction

“At the beginning of last year, we

equipment continues to prevail as

opened an ultramodern sales, parts and

customers are always looking for

service dealership in Middelburg to offer

the most cost-effective way to

responsive support and service across

move material.

our entire equipment product range to

Vaughan further comments that

Babcock will be representing

customers in the region. From this new

Volvo Construction Equipment and

flagship branch, we have been able to

Terex Trucks at the Mining Indaba at

deliver improved service and a faster

stand 807.

Education & Training

Preventing plastic welding errors Plastic welding relies on the same principles as steel welding, yet there is still limited knowledge as to these standards and requirements in South Africa. Ian Venter* discusses preventing potential welding errors in plastic pipes.

here is a distinct lack of plastic

to transfer adequate energy into

Preventing welding errors

pipe welding training facilities

the pipe to get a proper welding is

The amount of effort put in at the

in South Africa; most welders

needed. If one doesn’t understand the

beginning of the welding job will

who can do the job have

relationship between temperature,

proportionally deliver the anticipated

experience, rather than training, to

time and pressure, it can be either

life expectancy. If a welder takes little

thank. In most cases, these perceived

over- or underdone.

care and pays minimal attention at

welding experts will conduct welding

the beginning of a job, the result will

according to information picked up

be adequate energy at the pipe ends,

be an inferior piping system. This results

from previous welders they’ve worked

but when the pipes are pushed too

in an increased chance of ending up

with, their own experience, or possibly

hard, the material squirts out, resulting in

with premature failures, which increase

previous formal training.

two hard faces against one another. It

downtime and maintenance costs.

In the mining environment, the life expectancy of piping systems is usually

may look like a weld, but it is not a weld.

One principle to remember is: measure twice, cut once. Good

not as extensive as in the civil industry

Component quality

and, when a life expectancy of 5 to 15

The other important aspect is the quality

implementation, and ensuring that the

years is adequate, a substandard weld

of the components that are welded.

correct equipment and procedures

might do. There are a few parameters

A good welder welding inferior-quality

are applied to prevent redoing the job

that are important to achieve the

components will still result in a “bad”

at a later stage. There is a long list of

life expectancy of plastic welding,

weld. Often, the standards and the

what can be prevented with a carefully

such as time, temperature and pressure. Calibrated equipment – such as temperature and pressure gauges and controls – is also an

One principle to remember is: measure twice, cut once

practice extends to proper training and

control aspects in the

executed welding job, including injuries,

process are there to ensure

downtime and environmental disasters.

both the competency of the welder and the quality

Techniques

of the input component

Different welding techniques should

– which can be a bend,

be used for different applications.

T, or an elbow. It basically

While electrofusion welding can be

extremely important element in plastic

protects the welder from the supplier of

used in a confined space, or high up

welding to extend the life of a system.

the pipe, and vice versa. Whichever is

in a structure, butt welding is normally

the weakest is the one that will be the

used in a trench or on the surface

cause of failure.

of an environment. When working

A good understanding of the required time to keep a pipe against the element

Pressure is also important. There could

Ins i de Mi n i n g 0 1 | 2 0 1 7

Education & Training

with extremely high-risk chemicals,

needs to be evaluated according to

such that he can get a weld factor of 1.

one needs to base the evaluation

SANS 10270.

Although the standards have been

criteria on the risk profile of the line.

available from SABS since 2004, they

For instance, a chemical plant may

Weld factor

be pumping sulfuric acid of 60% or

Once the welding is performed, and the

record them in their specification or

70% concentration at an elevated

visual inspection is done, the next step is to

tender documents, but don’t actually

temperature. After the weld is

determine the weld factor. The designer

validate the workmanship in line with

performed, it needs visual inspection

of the pipe system has the right to ask for

these standards. A well-documented flow

– ideally according to SANS 10268

a specific weld factor for his system – a

diagram of how the system needs to work

‘Inspection for welding defects’.

system with a weld factor of 1 means the

is equally as important.

Thereafter, it needs mechanical testing

welding is as strong as the pipe. In the

according to SANS 6269 and the

case of exclusion welding, the design of

*Ian Venter is the product specialist:

welders’ preliminary welding procedure

the specific geometry of the weld is now

Petroplas at Marley Pipe Systems.

are seldom enforced. Many people

Latest Equipment & Technology

Reducing risk with

top technology

As a global centre of mining excellence, WorleyParsons RSA expends a substantial amount of energy and resources on developing advanced solutions for its customers that will increase accuracy and efficiency, while reducing risk.

he project delivery and en-

bigger picture of their project.” Worley-

very efficiently. We were able to quickly

gineering consultancy has been

Parsons RSA began developing its inte-

identify value improvements by picking

developing a 5D project design

grated design project platform over five

up optimisation from the previous design

platform that integrates sophisti-

years ago, by integrating 3D intelligent

by using 5D technology. Optimisation is

cated technology tools in order to pro-

design data mapping with over 20 dif-

usually done after a project is finished

vide a greater degree of predictability

ferent engineering design processes and

– in this case, we used 5D technology

throughout the life cycle of an asset,

programmes creating a visual 5D design

in parallel with optimisation, saving

and, ultimately increase profits, even in

scope that incorporates schedule and

the customer time and money, while

the volatile commodity market.

cost. This 5D integrated project platform

concurrently identifying risks and value

“WorleyParsons does not develop new

approach has already been applied to

improvement propositions.”

systems. We ‘orchestrate’ the best avail-

a number of projects and has proven to

able standard systems so that they can

save customers time and money.

plug into each other,” says Henry Jonker,

address all the risks that were identified

general manager: Mining, WorleyParsons

Royal Bafokeng Platinum

RSA. “There are a number of power-

Mushir Khan, manager: Engineering, Wor-

tablishing value improvements to bring

ful engineering design processes and

leyParsons RSA, says that, by applying

costs down and improve construction

programmes that are used to improve

the integrated technology to the Front

schedules. For the BRPM project, by

efficiencies in mining and other sectors.

End Engineering Design (FEED) contract

using the integrated technology mod-

We are one of the first engineering con-

for Royal Bafokeng Platinum’s (BRPM)

el, WorleyParsons was able to do the

sultancies in the mining sector to develop

second phase 100 ktpm Merensky Con-

feasibility study and value improvement

methods that integrate these products to

centrator, the project was completed

simultaneously and determine 90% of the

combine the benefits of using them to-

very successfully and expediently. “This

dimensions and costs, enabling the next

gether. Essentially, we’re taking individual

is the first project where the integrated

phase – the detailed engineering – to be

puzzle pieces and figuring out how to slot

technology was applied to its fullest

undertaken quickly and very accurately,

them together to show our customers the

potential and it has proved to work

resulting in a predictable construction

Khan explains that the norm is to first complete a feasibility study and then

Ins i de Mi n i n g 0 1 | 2 0 1 7

in the feasibility stage, followed by es-

1 2 3 4 5

Horizontal gravity take-up structure and drive Plant incline conveyor Conveyor trestles and doghouse gantry Conveyor head frame and structural interface Conveyor tail frame structural and feed chute interface

cost. Khan says that this high level of accuracy is obtained by plugging real-time costs into a 3D parametric design module to create a cost-based estimate.

3D parametric designs “We can now seamlessly integrate 3D parametric designs in a 5D platform, making detailed engineering much easier and quicker, and enabling us to give our customers a far clearer overview of their projects,” he says. WorleyParsons RSA has been using parametric design for some time, particularly for bulk materials handling, to simulate how processes will work based on the specified parameters entered. Parametric design is a type of 3D modelling that can demonstrate how a product or process will function based on varying parameters or values. Parametric design models allow for flexible designs, 3D visualisation of a process as parameters change, and quicker designs. “WorleyParsons RSA will be applying integrated technology as a standard offering going forward on new projects,” says Murray Macnab, business development executive. He notes that, at a very low additional cost, customers are also

Realising possibilities from mine to market.

able to get an operational model as part of the offering. “With our integrated technology module, we can create the framework and groundwork to deliver a project to a predictable construction deliverable, and we can also take that same module and go into operations,” adds Khan. “All the data generated is electronic, so no more containers of paperwork that can get lost or damaged, or not be

Resource Evaluation

Mine Planning

Mining & Mine Development

Materials Handling

Environment & Approvals

Transport to Market

Non-Process Infrastructure

used again. Costing models can be imported straight into SAP, and all the data from a design model, such as parts suppliers, operational information about parts, etc. can be uploaded to a customer’s system. The data can also be used for simulation – for example, the operation of a plant or underground mine.

Generated data “A vast amount of data is generated as a project is set up,” continues Macnab. “As one of the ‘jigsaw pieces’ of our integrated technology offering, we can use the data to offer our customers a large degree of predictability over the life cycle of a project, and take guessing out of the equation. We cannot predict the selling price of commodities at any given time, but we can predict productivity and maintenance schedules, preventing unexpected shutdowns by using data that has been generated during the feasibility and engineering stages. By obtaining a further, small amount of information, customers can be informed and prepared about future productivity and maintenance issues, thereby mitigating cost risks. Globally, WorleyParsons has already been using this digital enterprise in the oil and gas sector to offer customers a

Mineral Processing

Tailings & Waste Management

Smelting & Refining

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.

greater degree of predictability. “Our objective is to ensure that all our services focus on reducing risk, while quantifying data to increase productivity,” concludes Macnab.

www.worleyparsons.com

wprsainfo@worleyparsons.com

Latest equipment & technology

Adhering to market requirements New technology brings about a host of benefits. This is typified by Atlas Copco’s new RTEX handheld pneumatic breaker, which reduces energy consumption by 50%, is 25% lighter, and can be used by both genders.

he pneumatic breaker uses a new operating principle – constant pressure control – to achieve record-breaking

efficiency. The innovative design of the breaker uses only half as much

RTEX FAST FACTS: • Weighs only 25 kg • Uses half the energy • Vibrates at below 5 m/s2 • More compact than traditional breakers

This means that a compressor only half the size of normal is needed, or two breakers can be used on a compressor that previously powered only one breaker. The result is a smaller investment in the compressor, reduced fuel consumption, easier transportation, and lower emissions. “From an energy

“It is a lowmaintenance type of product and advantageous for underground mines.” Neville Stewart, business line manager, Atlas Copco

Innovation Centre in Kalmar, Sweden, explains how the new technology works: “In a conventional breaker, air is discharged each time the acting piston moves up or down. In the RTEX, we discharge the air only once – on the piston´s return stroke. Then the constant pressure from a chamber on the top of the new breaker pushes the piston down.” He adds that the pressure on top of the acting piston is constant and it, therefore, does not generate vibrations

perspective, one thing that

improve the design of the machines,

as on conventional breakers, so there

Atlas Copco has

while taking into account things like

is no need for vibration damping. “To

been trying to do

fuel consumption. “One example is our

achieve this, we moved the valve from

for many years is

hydraulic breakers that have power

the top of the breaker to the bottom –

to make everything

adapt systems, meaning that some of

our new “Up-Side-Down” concept. The

as efficient and

the energy goes back in the breaker

new, longer and heavier piston trans-

effective as possible.

instead of into the carrier. This brings

fers power much more efficiently to the

We have been striving

about savings in fuel consumption,

unique RHEX power chisel. Even though

to reduce energy

lessens wear and tear, and prolongs

the RTEX can work with conventional

costs, vibration levels,

the lifespan of the machine.”

chisels, the RHEX is specially tuned to

and noise levels, while

According to Stewart, the RTEX looks

increasing health and

like a normal breaker and is a straight-

optimal shockwave interaction for bet-

safety, and trying to

case machine, but it uses half of the

ter breaking performance.

make everything as

air, and both genders can use the

productive as possible,”

machine. “It is a low-maintenance

tip profile, which significantly reduces

says Neville Stewart,

type of product and advantageous for

jamming. The new RTEX working

business line manager,

underground mines.”

principle, long piston and RHEX

Atlas Copco. company is always looking for new ways to

Ins i de Mi n i n g 0 1 | 2 0 1 7

the new breaker in order to achieve

“The RHEX also has a special concave

chisel have resulted in record high

He says that the

Olof Östensson, an Atlas Copco engineer at the Construction Tool

compressed air and the RTEX weighs only 25 kg.

Neville Stewart, business line manager, Atlas Copco

efficiency – 50% less air is needed for

The RTEX makes use of a power chisel for better breaking performance

the same breaking capacity,” concludes Östensson.

Latest equipment & technology

Design for better safety Higher safety levels and huge savings can be achieved when highquality material is used to manufacture components. Adding excellent design and precision to the fabrication will result in products of distinction, writes Mientjie Kleinhans.

hen designing or

deliver the life expectancy or safety

redesigning new

standards. “Buying cheaply

components for a mine, or

often becomes very

any industry, the designer

expensive, because

has to keep various factors in mind, such

product failure

as safety, cost and energy savings. Vital

or replacement

Engineering’s approach regarding safety

usually result

in mines is “total quality management”

in unplanned

(TQM), according to Dodds Pringle,

downtime. This

managing director, Vital Engineering.

results in revisiting

“Adhering to TQM, and using quality

material was

the initial installation,

used to produce the floor grating panel – can it withstand the

plant and equipment, leads to huge

doing it all over again,

savings in the long run. It means that a

at an additional cost,”

environment’s conditions?

mine won’t have to replace products

explains Pringle.

Then, if a panel fails, what

or equipment as frequently. Exceptional

He warns that companies

is the direct result? The area

product quality generally stems from

should, however, be careful not

will most probably be cordoned off

both good design and the use of high-

to overprice products either.

until the panel can be replaced,

quality materials. If high-quality material

“Pricing needs to be fit for purpose.

which means downtime and loss of

is used, but the product is designed

Excessive pricing can have such

production for the mine. Mines cannot

cheaply, the desired result will not be

an impact on the cost of a mine

afford safety hazards or downtime.

achieved,” says Pringle.

that it drives operations into a zone

To ensure safety in mines, there should also be more involvement in terms of specification adherence in the procurement process. “For example, there should be safety officer involvement, some sort of history of the product being purchased, what the cycle time of the product is in terms of maintenance, whether there have been any fatalities due to product

of unprofitability.”

“Buying cheaply often becomes very expensive, because product failure or replacement usually result in unplanned downtime.” Dodds Pringle, managing director, Vital Engineering

Companies that design and manufacture components for the

He adds that the

mining industry always need to keep

criticality of the product

such factors in mind when formulating

has to be analysed,

and fabricating product. From

meaning: were a

patented grating panel clips for light,

specific component

medium and heavy applications, to

to break, what would

pressure-forged gratings manufactured

the direct result of

to international standards, Vital

its failure be? Would

Engineering only uses the best-grade

failure result in possible

steel and material in its products.

fatalities, downtime, or

“Furthermore, when it comes to

have no effect on the

installing products on mines in remote

safety or production of

locations, we always carry out

the mine?

extensive pre-installation studies and

Another factor

layouts prior to shipping. This ensures

that needs to be

that, when actual installation takes

considered when

place, this phase of the operation is

procuring or designing

swift and efficient, with no expensive reworking required.

failure, and also what the lifespan of

a product is the location of the mine.

the product is. Those aspects should be

If a mine is located in a remote

in some form of a tick-box standard,”

area that is hard to reach, it makes

standards of our products, safety

says Pringle.

sense to install high-quality and

and workmanship; and hasten to

better-designed components.

warn mines out there that, by using

Safety over cost

Pringle provides an example of the

“We are proud of the high

unspecified materials, or allowing

It is possible to import low-cost products

walkways in processing plants. “The first

substandard workmanship, one is

but, in the long run, this may not

crucial element to think about is what

courting disaster,” concludes Pringle.

In sid e M in in g 0 1 | 2017

MARKET news

Laboratory Analysis

from around the continent Opening new doors Superior control Optimised materials handling systems on mines can ensure unimpeded material flow by managing belt control and presentation controls. Weba Chute Systems helps mines to manage the flow of materials using a customised transfer point system. This method provides a chute system designed to take specific operating parameters into account. “These parameters can include anything from a need to control belt presentation to reducing spillage, dust and noise, and, importantly, to control flow so that wear is minimised,” explains Mark Baller, managing director, Weba Chute Systems. The design process is considered the most important stage of any project at Weba Chute Systems. Once the data received from the customer has been verified, extensive use is made of sophisticated 3D computer software to arrive at what is considered the optimum design for the application in question. Terex TER001_30 Crane.qxp_Layout 1 2016/12/14 1:21 PM Page 1

Ins i de Mi n i n g 0 1 | 2 0 1 7

Supplying mining equipment solutions Zambia’s Chambishi copper mine will be supplied with the necessary equipment and skills to effectively mine the lucrative South East Ore Body by Sandvik Mining and Rock Technology beginning in March 2017 and running through 2020. Sandvik Zambia will supply a comprehensive solution that will include automation of the mine, equipment, services, training and the company’s unique Trans4Mine optimisation programme. “We believe this is just the start of a bright partnership with NFCA and its mother-company, China Nonferrous Metal Mining Co. Ltd,” said Daniel Banister, sales area manager: Central Africa, Sandvik Mining and Rock Technology. Donghong Zhang, senior deputy-CEO, NFCA, commended the company on its ability to leverage its local and international expertise to find solutions for the Chambishi mine.

Keeping the lights on at quarries and mines The mobile and free-standing lighting tower solutions from Pilot Crushtec International has ensured Mpumalanga coal mining specialist Just Coal can continue operations, when and where required, for an unbroken 24 hours without refuelling. Driven by a Lombardini diesel motor with a 75 ℓ tank, the TowerLight VT8 units have enabled Just Coal’s new Spring Forest opencast mining site to work safely and efficiently around the clock “Apart from their lighting performance, they have impressed with their reliability

TowerLights are the ideal lighting solution for mining and quarrying applications, road works and construction sites, outdoor events and as a source of income to the rental industry

and ease of transportation. The TowerLight telescopic lighting mast is regarded as a major safety feature and is easy to raise and lower. Previous experience with designs based on folding towers had proved them to be unstable, dangerous as well as prone to damaging the lights themselves,” explained Sandro Scherf, CEO, Pilot Crushtec International. At 8 metres high, each unit can illuminate an area of up to 3 800 m², meaning maximum benefits for mining and quarrying applications.

In sid e M in in g 0 1 | 2017

Hear from the most influential executives active in investing and developing mining projects on the African continent: ANNOUNCING SOME OF THE LATEST SPEAKERS TO BE ADDED TO THE AGENDA

RICK RULE President and CEO Sprott U.S. Holdings Inc.

MARK CUTIFANI Chief Executive Officer Anglo American

6-9 FEB 2017 CAPE TOWN | SOUTH AFRICA

ALAN DAVIES Chief Executive Officer Energy & Minerals Rio Tinto

ROBERT FRIEDLAND Executive Chairman and founder Ivanhoe Mines

DR. DAMBISA MOYO Macroeconomist

SAVE AN ADDITIONAL 10% on your delegate registration. Mention the required offer code PAIM3 for discount.

STAY CONNECTED

#miningindaba | www.miningindaba.com

Good advice and

quality data

oday’s business paradigms have undoubtedly shifted, especially for mining projects. To ensure profitable operations, longevity and sustainability, good relationships with suppliers have become

crucial, as has obtaining good advice and quality data early on in the planning phases. Technology also needs to be high on the agenda when choosing project strategy – as falling productivity in mining threatens the industry’s sustainability globally. “With today’s productivity levels 25% to 30% lower than a decade ago, it is not enough for mines to focus on isolated areas of operation for a magic bullet. Progress in mining will shift from how well the operation moves material to how well it collects, analyses and acts on information to move material more productively,” says Roger Dixon, corporate consultant, SRK Consulting.

Water and energy Other key factors for new projects are access to water and energy, as competition for these scarce resources grows and the likelihood of conflict with stakeholders rises. It is a well-known fact that much of Africa struggles with energy constraints, with rising electricity prices or a lack of infrastructure. This means that addressing higher risks, better efficiencies and smarter application must be included in today’s mine energy designs. According to Noddy McGeorge, principal mining engineer, SRK Consulting, energy planning could include altering production plans to meet the needs of load balancing, exploring energy recovery systems and installing more secure power sources on-site. SRK will be showcasing its 360-degree mining perspective at its exhibition booth at the 2017 Investing in African Mining Indaba in Cape Town in February 2017.

Roger Dixon, corporate consultant, SRK Consulting

Noddy McGeorge, principal mining engineer, SRK Consulting

EVENTS

Reduced rates for Mining Indaba The organisers of the Investing in African Mining Indaba announced that registration fees for mining and exploration companies have been reduced, by as much as 50%.

he reason for the reduction

In addition to these

in registration fees is a reaction

price reductions, the indaba

to the market conditions and

will introduce new ways for people

unfavourable currency conversion

to connect and meet. Improvements

• Dan Kazungu, Mining Cabinet

rates that have resulted in lower

will include the expansion of the

attendance recently.

commodity-specific, speed-networking

• Nick Holland, CEO, Goldfields.

programme and the networking

The agenda for 2017 has been

round tables.

developed to take advantage of

“We want to ensure that mining companies meet investors who are

Secretary, Kenya

“Those enhancements – along

eager to learn about their projects.

renewed growth. The event will also

Towards that end, we need to attract

with remarkable speakers, heated

focus on battery metals and more

the mining companies. This new

panel discussions, mining company

Chinese and Asian companies will also

pricing will help to make that possible,

presentations, country case studies

be involved at Mining Indaba.

especially for the junior miners,” says

and thought-provoking research – will

Jonathan Moore, managing director,

make the 2017 indaba an invaluable

Indaba events

Mining Indaba. He added that investors

experience for all who are working

The indaba is more than an exhibition

and mining ministers are again invited to

towards improving the state of mining in

space and will again host various events:

attend at no cost.

Africa,” says Moore.

• networking round tables

Mining company attendees reported

• speed-networking opportunities

that market conditions and poor

Speakers

currency conversion rates made it

As always, there will be many speakers

• special information sessions

difficult to send all those who should

at the event, which include:

• mining thought leadership

participate in the conference in 2015.

• Robert Friedland, executive chairman

“It’s clear that this had an impact

• corporate mining presentations

on event equilibrium,” says Moore.

development day.

• Mark Bristow, CEO,

The number of investors at the 2016

presentations • young leaders career

and founder, Ivanhoe Mines

The event will again take place in Cape

Randgold Resources

Mining Indaba more than doubled,

• Dambia Moyo, macroeconomist

Town, from 6 to 9 February 2017, and the

and attendance from African and non-

• Rick Rule, president and CEO,

organisers expect to draw companies

African governments was also strong.

from various mining-related industries.

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IBC

Joest

BME

OFC

KSB Pumps

BMG

Micromine

Trysome

Cummins

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