Inside Mining July 2014 by 3S Media

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AFRIC AN UPDATES ON THE

ining GROUND AND UNDERGROUND

WESIZWE’S BAKUBUNG AKUBUNG Flagship platinum num mine achieves a major milestone ajor milest tonee OTJIKOTO GOLD LD MINE Namibia's biggest ggest gold mine

AKHANI GROUP All-encompassing compa assiing so solutions olutio ons for mining ning in nA Africa frica TAILINGS MANAGEMENT NAGEMENT AT NAMOYA Wastewater solution for DRC gold project ject A FRESH APPROACH ROACH IN AFRICA The interface between mining and infrastructure nfrastructure SITE PSYCHOLOGIST Charissa Bloomberg on uplifting workers and management ISSN 1999-8872 • R50.00 (incl. VAT) • Vol. 7 • No. 7 • July 2014

2014

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CONTENTS

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

ining

July 2014

GROUND AND UNDERGROUND

ENDORSED BY

EDITORâ&#x20AC;&#x2122;S COMMENT ON THE COVER O

3 Infrastructure in Africa

B Building the future TThe newly established Akhani G Group, which is 51% blackffemale owned and B-BBEE 3 rrated, is one of the biggest sservice providers in the South A African mining industry, with p plans to expand through Africa.

INDUSTRY COMMENT

5 Integrating Africa AFRICA ROUND-UP

6 Mining news from the continent IN THE SPOTLIGHT

12 The future of

mining

GOLD & PGM

14 Bakubung: a model of optimisation 16 Building a gold mine will cost you dearly 18 Size counts at Otjikoto 20 Tailings management at Namoya 22 Striking gold at Kibali in DRC 24 Impala Opencast finally complete INFRASTRUCTURE

26 A fresh approach in Africa 28 Dingleton on the move 29 Huge fans of Maseve 30 1 200 tonne trusses at Sentinel 31 Mining firms head north 32 Complete solution for emergency vehicles 33 Altaaqa Global in Africa 34 At the top of its game HEALTH & SAFETY

36 New paradigm 38 Illuminating the way 39 Mining suppliers beware 40 Training for safer mines 42 The site psychologist 20

MATERIALS HANDLING

44 Conveying what others cannot 46 From static to mobile conveying 48 Thinner yet stronger 49 Splitting airs 50 A crushing success 52 Cyclone efficiency boost 53 Slick lubrication solutions 54 Forklifts go 4WD 55 Lock out potential hazards INDUSTRY NEWS

56 BME pays tribute to its people IN SID E M IN IN G 0 7 | 2014

EDITOR'S COMMENT

Publisher Elizabeth Shorten Editor Gerhard Hope Online editor Sylvester Haskins Head of design Frédérick Danton Senior designer Hayley Mendelow Designer Kirsty Galloway Chief sub-editor Tristan Snijders Sub-editor Beatrix Knopjes Contributors Charles Brewer, Nico Pienaar, Cecil Naude Production manager Antois-Leigh Botma Production coordinator Jacqueline Modise

Infrastructure in Africa

Marketing manager Hestelle Robinson Digital manager Esther Louw Financial manager Andrew Lobban Administration Tonya Hebenton Distribution manager Nomsa Masina Distribution coordinator Asha Pursotham Printers United Litho Johannesburg Tel: +27 (0)11 402 0571 ___________________________________ Advertising Sales

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South Africa: R550.00 (incl VAT & postage) African countries: US$80 Foreign: US$100 Email: subs@3smedia.co.za ISSN 1999-8872 Inside Mining Copyright 2014. All rights reserved. ___________________________________ All material in Inside Mining is copyright protected and may not be reproduced either in whole or in part without the prior written permission of the publisher. The views of contributors do not necessarily reflect those of the publishers.

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T IS OFFICIAL: 2013 was one of the most difficult years ever for the global mining industry, according to PwC’s annual mine report, which analysed 40 of the largest mining companies. Commodity prices, led by gold’s greatest annual decline in over 30 years, decreased significantly, with the result that mining stocks fell 23%. Together with record impairments, this has meant that profitability in the mining industry was at its lowest level in a decade. However, it is not all doom and gloom. Despite diminished profitability and shrinking cash, underlying performance in the mining industry, as represented by adjusted EBITDA, astonishingly withstood the tough conditions, and was only down 8% in 2013. Dividend yields also continued to increase, with gross dividends paid up 5% and dividend yields slightly up to 4%. John Gravelle, of global mining leader PwC, points out that there are new faces at the helm of almost half of the largest 40 mining companies in the last two years. For the first time, 2013 saw the majority of the 40 largest mining companies come from emerging markets. Given the current performance and greater appetite of these companies to spend on capital, PwC is confident that this trend is set to continue. The change in the global mining landscape also saw a divergence in the collective performance between emerging market companies and their developed market counterparts. Net profits in 2013 from emerging market companies were $24 billion in aggregate, compared to an aggregate net loss of $4 billion for developed market companies, impacted particularly by impairments. Against this backdrop, the licence to operate in all corners of the globe is becoming more challenging, with governments increasingly eager to expand their share of royalties and taxes. “The question remains as to who will be bold enough to thrive in these difficult times,” comments Gravelle. “This year has seen some traces of calm return to mining markets, with market capitalisation for the largest 40 miners stable; evidence that some level of confidence may be returning.” An indirect sign of this nascent confidence is the integration of the Concor Civils and Concor Roads & Earthworks divisions of Murray & Roberts into a new division known as Murray & Roberts Infrastructure. The new company aims to tackle the infrastructure deficit in Africa, in particular, which represents a major hurdle for mining companies. In an exclusive interview, managing director Eric Wisse tells Inside Mining that the interface between mining and infrastructure is a vibrant market space. With mining companies increasingly looking at corporate social investment initiatives, such as housing for mineworkers, spurred in part by the requirements of the Mining Charter, Murray & Roberts Infrastructure is ideally placed to become a major player. Another exciting new company is the Akhani Group, formed from the merger of three different service providers, together with a recent partnership with another company to offer energy management and alternative solutions to the mining industry on the continent. Billing itself as one of the largest service providers to mining in Africa, we look forward to seeing what CEO Fulu Mphuthi can bring to the industry. Gerhard Hope

IN SID E M IN IN G 0 7 | 2014

INDUSTRY COMMENT

Integrating Africa A key topic of discussion at the recent 24th World Economic Forum on Africa was the need to boost intra-Africa trade significantly.

HIS SENTIMENT IS echoed by Charles Brewer, managing director of DHL Express in sub-Saharan Africa, who attended the forum which took place in Abuja, Nigeria from 7 to 9 May. “There was a collective consensus among African leaders on the topic of mobility in Africa, as well as the importance of efficient border and visa policies. We have seen good follow-up particularly in East Africa and it is imperative to continue to work on the border and customs environment to grow intra-Africa trade,” says Brewer. The forum took place against a backdrop of significant economic growth in Nigeria – having recently overtaken South Africa as the largest economy in Africa – and that this has spurred investment interest in the country. “Africa is clearly on the global agenda. Despite security concerns, delegates and heads of state from all parts of the world gathered in Abuja to discuss inclusive growth for Africa.” A key view expressed by a number of African leaders at the Forum was the need for a proactive approach to border management, which will enable trade between various regions. The creation of an environment that enables business growth on the continent, as opposed to obstructing it, was also addressed by various parties.

Drivers to integrate, develop the region Recognising the importance of travel facilitation and talent mobility as drivers to integrate and develop the region, President Paul Kagame of Rwanda, President Uhuru Kenyatta of Kenya and Prime Minister Moussa Mara of Mali have all signed ‘The Call to Action on Travel Facilitation and Talent Mobility’, which urges all African States to work together towards the

establishment of joint policies and the removal of barriers to facilitate movement of people. Brewer adds it was also positive to witness how small and medium enterprises (SMEs) are increasingly being recognised as the primary driver of economic growth in Africa, and how they are being supported across Africa.

various regions. “Infrastructure is vital for connecting regions and, by improving this, the number of investments within Africa will grow exponentially, creating further opportunities for its people.” In order to fuel the continent’s momentum, sustained trade from international markets, as well as intra-Africa

“Mining and the protection of the environment do not have to be on a collision path.” Charles Brewer, managing director, DHL Express, sub-Saharan Africa

“A growing SME base will create thousands of new jobs, which is an absolute must for this ever-growing continent, as it is a critical driver of sustainable economic growth.” Some of the challenges SMEs face include infrastructure challenges and customs regulations and controls. “The fact that world leaders have recognised these issues and put actions in place towards easing the difficulties experienced can only bode well for future business development and success on the continent.”

Chinese commitment to infrastructure Brewer points to the commitment made by the Chinese government to prioritise infrastructure development in African, which is necessary in order to develop connectivity and promote trade between

trade, is needed. “If Africa is to compete with global, advanced countries, investment is needed in facilitating trade and the ease of doing business,” concludes Brewer. ABOUT THE COMPANY DHL is the global market leader in the logistics industry. It commits its expertise in international express, air and ocean freight, road and rail transportation, contract logistics and international mail services to its customers. A global network composed of more than 220 countries and territories and about 285 000 employees worldwide offers customers superior service quality and local knowledge to satisfy their supply-chain requirements.

IN SID E M IN IN G 0 7 | 2014

AFRICA ROUND-UP

SENEGAL Bas-

MINING NEWS

from around the continent

TANZANIA The Uongozi Institute of Tanzania, which supports African leaders to attain sustainable development, is conducting a benchmarking exercise for the extractive sector on behalf of the government. The institute is designing a programme that will help the government scale up its negotiation skills in the extractive sector, while assisting bureaucrats with sharpening their skills on policy frameworks, contracts and transactions. The benchmarking exercise will look at the weaknesses and strengths 6

of the sector, with the view to formulating a programme that addresses the current challenges in the industry. Uongozi Institute CEO Professor Joseph Semboja said that, as the government proceeds with formulating legislation and policy for the sector, their input will be used through a panel of experts that advises the government on the same. “We will come up with a purely technical report on all these issues including contracts, taxes, revenues, environment, local content, governance and management, among others,” said Semboja.

sari Resources has released feasibility study results for its Makabingui gold project in Senegal. These outlined a low-cost, highly profitable operation with significant free cash flows, reported the Australian-listed company, which is focused on discovering gold deposits on the Birimian gold belt in West Africa. “Our focus on profit and building a robust business case enables the company to add considerable value for shareholders and the strong potential to leverage the upside as additional high-grade resources are added through further infill drilling,” commented Bassari managing director, Jozsef Patarica.

MALI The final metallurgical testwork programme for the Fe-

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kola Gold Project in south-western Mali has been completed as part of a definitive feasibility study, reports Papillon Resources. This supports the previous decision to implement a conventional primary crush, semi-autogenous grinding and ball mill circuit, together with gravity concentration and carbon-in-leach processing. “The recent metallurgical testwork results reconfirm the technical viability of Fekola,” said Papillon managing director and CEO Mark Connelly. The testwork has shown a number of improvements compared with the prefeasibility metallurgical profile. This included small increases in expected recovery, especially at lower head grades, and also significant reductions in cyanide consumption.

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AFRICA ROUND-UP

LESOTHO Following completion of the Liqhobong diamond mine financing in May, Firestone Diamonds has reported that construction and development is expected to take 24 months. The company said that nameplate production of 300Â 000Â tonnes is expected to be achieved in H1 2016, with the main treatment plant and supporting infrastructure already underway, under the leadership of chief project officer Glen Black. About 73% of the EPCM budget had been committed to date, with major equipment deliveries aligned to its current baseline schedule. â&#x20AC;&#x153;I am pleased to announce commencement of the earthworks programme at Liqhobong in the Lesotho Highlands, which follows the recent completion of the financing,â&#x20AC;? commented Firestone CEO, Stuart Browne.

ZAMBIA Zambia cannot continue to rely on copper as its main source of revenue for economic growth, according to Vice President Guy Scott. Speaking at the opening of the 4th Zambia International Mining and Energy Conference in Lusaka, Scott warned mining companies that they may face discontent from people if benefits from the countryâ&#x20AC;&#x2122;s natural resources were not shared adequately, reported Post Zambia. Scott emphasised the need for Zambia to review its total dependence on copper. â&#x20AC;&#x153;I am not saying we should do away with copper, gold or mining of other minerals. We should look at economic growth in the long term, and the best way is to diversify into other sectors,â&#x20AC;? Scott said.

ZAMBIAâ&#x20AC;&#x2122;S biggest copper producer, First Quantum Minerals, has â&#x20AC;&#x2DC;slowed downâ&#x20AC;&#x2122; or postponed more than $1Â billion worth of capital expenditure in the country due to a tax dispute with the Zambian government. First Quantum operations director Matt Pascall said that subsequently there was an air of uncertainty hanging over its operations in the country. â&#x20AC;&#x153;Certainty is absolutely the critical thing that is required if we are going to look at any form of investment,â&#x20AC;? Pascall told Bloomberg News. Zambia is withholding more than $150Â million in value-added tax repayments from First Quantum, Pascall said. A 10% duty on exports of semi-processed copper ore, known as concentrates, has created a build-up at its Kansanshi

mine, now valued at $350 million. They have already invested about $2 billion in new mines.

GHANA Groundbreaking at the Asanko Gold Mine plant is expected to commence in August, pending a positive investment decision by the board in July. The siteâ&#x20AC;&#x2122;s early works programme has been progressing on schedule and on budget. In April, Asanko engaged DRA as the EPCM contractor for design and construction. Knight Piesold will design the tailings storage facility and carry out detailed geotechnical engineering works. A programme was subsequently initiated to advance the activities, allowing Asanko to maintain its project schedule, targeting first gold in Q1Â 2016. 7

IN SID E M IN IN G 0 7 | 2014

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COVER STORY

Building the future

AKHANI GROUP

The newly established Akhani Group, 51% black-female owned and B-BBEE Level 3 rated, is one of the biggest service providers in the South African mining industry, with plans to expand through Africa.

HE WORD AKHANI means “building the future together,” explains CEO Fulu Mphuthi. The group’s executive team includes Deon Fuhri as COO and Ntaoleng Kunene as CIO. The group was formed in May through the merger of Mine Procurement Solutions (MPS) and Vhaselwa Engineering & Management Consulting (VEM). MPS comprises MPS South Africa, MPS Tanzania and MPS Mozambique and MPS Liberia. In addition, Akhani recently an-

“I believe that the formation of the Akhani Group will inspire other black female entrepreneurs in the mining industry.” Fulu Mphuthi, CEO, Akhani Group nounced a partnership with Energy Cybernetics, a local energy-management services company based in Pretoria. This will allow the group to identify renewable energy and energy-efficiency opportunities in sub-Saharan Africa.

LEFT COO Deon Fuhri, CEO Fulu Mphuthi (seated) and CIO Ntaoleng Kunene OPPOSITE Two leading service providers for mining, oil and gas and energy management have combined forces in the Akhani Group

IN SII DE MI NI INS N I NG NG 06 7 | 2014

COVER STORY

The merger of the two leading service providers for mining, oil and gas, and energy management companies creates a comprehensive offering of workforce effectiveness and productivity, and operational performance excellence for the broader energy and resources industries. Akhani serves public, government and private market sectors.

Improved business performance With existing operations in South Africa, Mozambique, Tanzania and Liberia, the group intends to establish a foothold in Zimbabwe and Kenya by 2015. This forms part of its mission statement, which is to create value for stakeholders by enabling improved business performance for customers while enhancing quality of life. The merger has effectively combined, and leveraged, two already successful South African companies, with a good track record in infrastructure design and supply, workforce and operational camping-site management and maintenance, energy consulting, energy conservation and energy management, as well as transformation and change management A major feature of the new group is that it is 51% black female-owned, as well as being B-BBEE Level 3 rated. “Women empowerment is a big issue in South Africa at the moment, especially in white male-dominated industries such as mining,” says Mphuthi. “The formation of Akhani is another indication it is not a myth that a company with black female ownership can still

thrive in this sector. I further believe that the formation of the Akhani Group will inspire other black female entrepreneurs in the mining industry, and that if you stay true to your core values, continue to deliver value-for-money and build lasting relationships, you will achieve.”

Rationale behind the merger Mphuthi explains the rationale behind the merger: “VEM Consulting is strong in transformation management, while MPS is a well-known and reputable camp-site management player in the mining industry. Since VEM Consulting has always had an interest expanding its services into the mining sector, especially within Africa, we were interested to merge in order for us to be able to do that. In addition, our services and products complement each other.” Fuhri adds that MPS is “very strong in camp infrastructure design for the mining sector in Africa. We have been on the lookout for opportunities within South Africa for some time, and when the opportunity presented itself to enter into discussions with VEM Consulting, we quickly identified potential synergies, but also realised that we had similar values and visions.” These similarities paved the way for a smooth merger that only took three months to complete which, compared to traditional merger-and-acquisition transactions in the market at present, must be considered quick. “This transaction will create a leading camp management company,

differentiated by its ability to deliver the most innovative products and services and superior customer experience within the highly competitive and dynamic marketplace in which we operate. We are looking forward to working with Ms. Mphuthi’s team as we bring our companies together to deliver,” says Fuhri. “This combination creates a company that delivers maximum value for our shareholders, enormous opportunities for our employees, and a superior experience for our customers.”

No duplications Another benefit of the merger for customers in particular is that it has removed any operational or service duplication. “A client might require a basket of services, some of which may lie within the MPS framework and some within the VEM Consulting framework. We can now offer that with the Akhani brand.” Fuhri elaborates on Akhani’s main business proposition: “We believe we are the only service provider in the mining sector, and we are talking remote sites specifically, offering a basket of services that is all-encompassing. We carry out infrastructure design, development, manufacturing and commissioning. In addition, we also manage those camps on behalf of our clients, which include services such as catering, housekeeping, laundry services, landscaping and hotel/motel services. “In addition, we believe we are extremely well positioned to bring a unique service offering, which is an alternative energy

IN SID E M IN IN G 0 7 | 2014

COVER STORY

solution,” says Fuhri. This is critical, as off-grid power generation consumes about 30% of a mine’s operating expenditure. “In conjunction with Energy Cybernetics, we are in a position to provide alternative energy solutions that will save mining companies up to 20% of their energy consumption, which represents an enormous cost-saving.”

Energy-management sector Fuhri says that Akhani’s entry into the energy-management sector is based on a holistic service offering. “What makes our basket of products in the energy space so unique is it is not only a solar solution. At this particular point in time, we are steering away from wind energy because most mine sites are not situated on the coast, so wind energy does not play a factor. What we also offer as alternative power sources, apart from solar energy, is so-called ‘new age’ power generation. “We have agreements in place with manufacturers of solar air-conditioners and solar geysers. In certain countries we are also allowed to import diesel to reduce costs further. This enables us to approach mining clients with a complete basket of services. What we also offer at the moment,

20%

Energy saving for mines due to Energy Cybernetics

10 INS I DE MI NI NG 0 7 | 2 0 1 4

LEFT Camp infrastructure design and provision is a strong focus

“Our training methodology has to be very stringent because we mostly employ people unskilled labourers in these remote locations. Different cultures and language barriers are also a challenge we face when mobilising and operating these camps. We invest a great deal of resources developing the skills of our employees. We focus on basic skills and continuously review high-quality leadership development, and have a range of more than 26 external and internal development programmes currently in use across the group.”

BELOW Alternative energy solutions are another value-added service

which is quite unique in our industry, is a free energy audit for mining companies. “Our qualified energy managers and energy technicians will spend two or three days on-site, demonstrating to our clients that our solutions we propose will actually save them on their operating costs. The mining sector globally is under a huge amount of pressure from a capital expenditure perspective, while operating mines are equally under pressure to cut their running costs,” comments Fuhri. “While our head office will remain in South Africa, we are an African company, and we will increase our footprint on the continent as opportunities present themselves. Currently, we have offices in Liberia, Mozambique and Tanzania,” says Fuhri. He adds that Akhani’s focus on community development and sustainability on the sites it manages on behalf of its clients takes centre stage. “In most cases, we are the largest single service provider to the mining sector on a particular site. About 97% of all our staff on a remote site comes from local villages surrounding these camps. We work in partnership with local institutions and NGOs to hire and train local personnel.

t +27 (0)11 083 6403 • www.akhani.co

ABOUT MINE PROCUREMENT SOLUTIONS (MPS) MPS, a division of the Akhani Group, specialises in the infrastructure design, management and maintenance of remote workforce and operational camping sites. The division provides accommodation supply, catering, camp management and a complete range of associated services. The team of mining procurement specialists supports customers from conception to operation and maintenance, including community-development needs. The focus of the division is on quality and service delivery, safety at all times and project outcomes that are within budget and on time. ABOUT VHASELWA ENGINEERING & MANAGEMENT CONSULTING (VEM CONSULTING) VEM Consulting, a division of the Akhani Group, provides business transformation solutions that help customers effectively manage their enterprise more efficiently, safely and sustainably. VEM Consulting renders its consulting services to customers in South Africa with the intent of expanding its service offering globally. The division identifies business needs, determining solutions for business problems. Solutions entail alignment of business strategy, business systems, business process optimisation, organisational change as well as policy and procedure development, directly benefiting customers’ operational business performance.

In each issue, Inside Mining offers advertisers the opportunity to promote their company’s products and services to the appropriate audience by booking the prime position of the front cover which includes a two-page feature article. The magazine offers advertisers an ideal platform to ensure the maximum exposure of their brand. Please call +27(0)11 465 5452 to secure your booking.

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IN THE SPOTLIGHT

The future of mining The University of the Witwatersrand’s School of Mining Engineering hosted a mining industry forum on 21 and 22 May, with a focus on the application of technology in mining. By Sylvester Haskins

HE TWO-DAY FORUM was co-hosted by mining engineering group Sandvik Mining, and presented a platform for a range of technology specialists to engage fellow mining peers and the media on the latest technologies and best practice applied to the mining industry. Topical highlights in the two-day conference included an insight into next-generation coal-cutting and benefits, the future of coal load-and-haul, latest developments in surface-drilling tools and the effects of mechanisation on employment. Centre for Mechanised Mining Systems director Professor Jim Porter, in his presentation entitled ‘Challenges in technology change – the things you don’t see coming’, said that the integration of technology and people in mining systems is a challenge in the mining industry, despite South Africa being a recognised innovator in areas ranging from rock-mass stability to winder-rope design. Mining engineer and Wits University lecturer in beneficiation economics

12 INS I DE MI NI NG 0 7 | 2 0 1 4

Paseka Leeuw discussed the ‘Effect of mining mechanisation on employment’, while Professor of Mine Surveying and Head of the School of Mining Engineering at Wits University, Professor Fred Cawood, spoke on the ‘Future of mining research at Wits University’.

“In the next 20 to 30 years, there will be a huge change in mining layout, and it will become important to manage ore resources with the management of the workforce, and we will also experience a revolution in communication technologies,” said Professor Cawood.

Technology in harsh environments

Better economics

In his presentation, Professor Cawood stated that making technology work in harsh underground environments would

In addition, sustainable development is a key factor in mining operations going forward, and this implies safer mines, smaller environmental impacts and better economics. An investment in future mining technology is essential, and mechanised and automation in mining achieves better economics, explained Professor Cawood. The technology spheres in mining include ID scanning, X-ray systems, digital data processing, modelling in 3D space and developing satellite systems. “We require an extension of satellite technology in underground mining. Also, we need reliable and stable communication systems,” said Professor Cawood. He added that zero harm in mines required digital sensing, while

“In the next 20 to 30 years, there will be a huge change in mining layout.” be the challenge in the mining industry over the next three years. He said that digital technology can help in understanding environments better, as margins for profits in mining get smaller, calling for a different way of doing things.

IN THE SPOTLIGHT

technologies such as the scanning of fever to assess miner sickness are needed. According to Professor Cawood, the vision in applying technology to mining is to achieve safety, efficiency and reliable underground data in real time. The goal is to develop a mock-up mine and develop a ‘smart’ mine laboratory for hosting digital technologies.

Technology vs jobs As the use of new technologies in mining increases, fewer jobs will be created in the sector, said Leeuw. However, Leeuw believed that greater technology intensity in mining would have spill-over benefits for mining contractors and OEMS, thus creating jobs in other industries in South Africa. He said that technology will play an important role in the sector through alleviating safety pressures, while also attracting youngsters as the current workforce matures.

Mechanical blasting Electronic detonation systems supplier DetNet CEO Gys Landman briefly discussed the automation and advancements in mechanical blasting in the mining industry. He said that blasting is particularly energy efficient, adding that it is still the preferred system in big rock breaking. Digitising and exploiting blasting information counts among the advancements made in blasting operations at mines. Other forward steps in the industry include creating information that links into future systems, more user-friendly blasting technology and integrated processes. Landman advocated that the longterm future of mining lay in the use autonomous detonation systems, which will promote greater safety and efficiency of blasting operations.

movements and trucking, according to Nico van Aarde, manager of market development and sales at Sandvik Mining Systems. He discussed the safety benefits of IPCC compared to conventional methods, and this included the reduction in truck-use at mine sites, with a reduction of about 30% in ancillary equipment, automation from a remote control room and greater energy efficiency being the key features of the system. “When comparing IPCC to trucking, there is a greater element of safety as there is less vehicle interaction. Also, when comparing electrical motors or conveyors versus diesel engines, we find that IPCC is more efficient,” said Van Aarde. Short life-of-mine may still require conventional hauling methods, he noted. However, with over 200 IPCC systems at mine sites worldwide, IPCC technology has taken off globally. Van Aarde said that IPCC projects undertaken by Sandvik internationally included contracts at the Zhungeer coal mine in Mongolia, China and a coal operation in Cologne, Germany. Other IPCC projects completed by Sandvik were located in Sweden, Brazil and other parts of Europe.

Exploration accuracy The challenge in underground exploration and drilling, and focus of technology development in this area, would be both accuracy and the speed of drilling functions, discussed Sandvik application manager Bjorn Gohre. “Accuracy and speed of drilling should indicate what is ahead,” he said. Gohre explained that greater accuracy and precision is achieved in down-thehole (DTH) drilling, and Sandvik designed its equipment around the forces exerted by DTH drilling, as opposed to adapting other types of drills to accommodate DTH drilling. Sandvik acquired three competitors in the hammer market and combined the best of each to develop the Sandvik reverse circulation (RC) hammer. Gohre said that RC drilling achieves uncontaminated sampling, faster penetration and lower operating costs. Past underground projects in which the RC hammer had been applied included dewatering wells, blasting holes in radioactive to broken rock and in-site injection and recovery wells. Design and drilling applications developed by Sandvik included surveying drill holes to develop 3D models for a resource plan, noted Gohre.

IPCC APPLICATION DRIVERS • Energy efficiency Conveying is more efficient than other mining-house transport • Material movement At least 10 Mtpa • Electric costs vs diesel Electricity price in $/kwh is less than 40% of diesel in $/ℓ • Less carbon emission Compared to 240 tonne truck • Operational space efficiency At least 100 metre cut-back width needed for IPCC installation • Less dust generation Use of conveyors reduces dust at mine site • Automation and safety IPCC removes large dump-truck activities

Conveying vs trucking In-pit crushing and conveying (IPCC) is a more efficient and safer alternative to conventional methods of material

OPPOSITE Sandvik’s MB650 bolter miner working underground at Mandalong Colliery in Australia RIGHT Sandvik’s AutoMine Rotary Drilling is the first fully autonomous rotary drilling solution. The system uses advanced GPS receivers, cameras and geo-fencing to drill and tram autonomously throughout a mine

IN SID E M IN IN G 0 7 | 2014 13

GOLD & PGM

Bakubung: a model of optimisation The cutting of the first station or level on the ventilation shaft represents a major milestone in Wesizwe Platinum’s flagship Bakubung mine, said COO Paul Smith. By Gerhard Hope

HIS LEVEL IS about 690 m below the shaft collar, about 45 m above the first intersection of the Merensky Reef. It is the top access of the new mine, designed specifically for ventilation exhaust, since it is situated on the ventilation shaft. It is from this point where horizontal development will commence, connecting it to the same level from the main shaft. “The drilling of the rock engineering modelled support has started in order to support any intersected geological feature or fault in the vicinity of where the stations will to be cut,” reported Wesizwe projects executive Jacob Mothomogolo. This latest milestone is just one of a slew of targets achieved so far this year, with continual progress in all aspects, from main shaft to ventilation shaft-sinking, the installation of fire-suppression systems, the pre-commissioning of the ventilation shaft winder and overall project-sinking. “At the end of April, the main shaft had reached a depth of 520 m and the project had sunk over 1 200 m in total,” confirmed Mothomogolo.

Optimisation study A major earlier highlight was the official approval of the Bakubung Optimisation Study (BOS) on 12 March by the Wesizwe board, aimed at bolstering the business case for the new platinum mine. “One of the reasons we embarked on the optimisation programme is to adapt to changes taking place in the industry,” said Mothomogolo. These changes include fluctuating LEFT Shaft-sinking OPPOSITE Main shaft headgear

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GOLD & PGM

ABOVE LEFT Main shaft winder ABOVE RIGHT Shaft drilling (jumbo)

metal prices, increased cost pressures, and challenging work conditions and social climate, noted Mothomogolo. “The objectives are not unusual: to decrease time to full production and improve the project value. Obviously it limits the working capital requirement. Improved maintenance, production, sustainability, operating costs and reduced business risk are all benefits. It was really quite a large and aggressive scope,” said Smith. A new completion date for the sinking of the main shaft has been set for October 2015, 85 days earlier than the initial date of January 2016. Similarly, the ventilation shaft is set to be completed 72 days earlier than the initial date of February 2017. The BOS has also resulted in a 26-month reduction in the time to full production, with the 230 ktpm production level now planned for October 2020, as opposed to December 2022.

Increased mine capacity In addition, an 8.7% increase in mine capacity has been realised, with 250 ktpm run-of-mine planned for at full capacity. This equates to an increase in the steadystate monthly production to 35 280 oz 4E/month, or 420 000 oz 4E/year, which equates to a 20% increase in the yearly production rate.

Planned (m) Main shaft 528 Ventilation 780 shaft Total 1 308

Actual (m) 518

Variance (m) -10

680

-100

1 198

-110

TABLE 1 Sinking performance as at 15 May 2014

Perhaps one of the most striking aspects of the optimisation plan is the move to full or semi-mechanised mining. The shortening of shafts, accommodated by the removal of underground crushing and bringing level development onto reef horizons (known as on-reef development), will result in a substantial reduction in off-reef development of about 402 000 m3. Conveyor belts will be used for ore transport and chair lifts for people transport. In addition, a third 6-metre-diameter raise bore shaft has been introduced to assist further with ventilation and logistics. The significantly improved ramp-up timeframe to full production is expected to slash the project’s nominal capex cost from R12.03 billion to R10.69 billion, Smith said. “The net change in project net present value is a positive R2.1 billion to R6.5 billion,” said Smith. The significantly lower off-reef development will result in substantial savings of R1.1 billion. Smith added that “an increase in expected operating costs over initial estimates” due to increased labour and power costs “had been factored in.”

KEY FACTS • Bakubung will have a lifespan of 30 years • It will produce 420 000 4E/year of PGMs at steady-state production • The project has a highly favourable 4E prill split (combined reefs, life-of-mine): platinum (62.4%), palladium (28%), rhodium (7.4%) and gold (2.2%) • The main shaft will have a hoisting capacity of 250 000 tonnes of ore a month • The first blast of the ventilation shaft took place in July 2012 • Main commissioning of the mine is scheduled for Q4 2018 • Full production will be achieved in 2021, two years earlier than originally plannedBakubung will employ 3 135 people at full production

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GOLD & PGM

Building a gold mine The cost of building a gold mine has increased significantly over the last decade, from $560/oz in 2004 to a staggering $2 300/oz in 2013. Based on data from mines under construction, capital costs are expected to peak in 2014, at almost $2 400/oz, reports SNL Metals & Mining in its ‘Strategies for Gold Reserves Replacement’ report.

HIS ANALYSIS WAS based on a three-year running average of capital costs per ounce of production capacity for 192 primary gold mines, with a capacity of at least 50 000 ounces a year, and which entered production from 2004 to 2013; in addition to 22 mines under construction and slated to begin production in 2014 or 2015. Mine redevelopments and expansions were not included, since these projects’ existing infrastructure makes them incomparable with new mine developments. The three-year running-average capital cost of capacity follows behind the trend set by the gold price. When gold prices increased sharply in 2006, producers responded by approving construction of more capital-intensive projects. The lag between the change in gold prices and the increased capital-cost intensity is simply the time required for construction of more capital-intensive projects, which began at earlier gold prices. While producers and prospective producers greatly curtailed capital spending in 2013 and to date in 2014, capital-cost intensity is expected to increase to almost $2 400/oz in 2014, before pulling back to about $1 900/oz in 2015. The cost of operating a mine after it is built has also increased over the last ten years. Weighted-average annual cash costs increased about 190% from less than $250/oz in 2004 to a peak of $708/oz in 2012, before pulling back GRAPH 1 Three-year running average of capital costs for new gold production, 2004-2015

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slightly to $702/oz in 2013. Fortunately for producers, annual average gold price increases mostly outpaced cash cost increases during the period, soaring 308% from $409/oz in 2004 to a peak of $1 669/oz in 2012. The only exception was a 15% drop in gold prices in 2013, which surpassed a 1% decrease in weighted-average cash costs for the year. Based on cash costs alone, it would seem that producers’ margins should be quite healthy. However, SNL Metals & Mining’s analysis indicates that the total costs of production (comprising reserves replacement, capital spending, operating costs and administration) kept closer pace with gold prices over the ten-year period. Meanwhile, as predicted in February, a 15% year-on-year drop in the gold price

in 2013 forced mining companies to lower the prices they used to calculate their gold reserves. As the gold price climbed steadily from 2002 to 2012, gold producers increased their reserves calculation prices to allow profitable mining of lower-grade, higher-cost ores. Examining the nine-year reserves history of five major producers – Barrick Gold, Newmont Mining, Goldcorp, AngloGold Ashanti and Kinross Gold – shows a 14% weighted-average decline in their reserves prices from 2012, an 11% average decline in their total reserves (net of changes due to acquisitions, divestitures, and production), and an 8% increase in their weighted-average reserves gold grade. Barrick ended 2012 with 140.2 million ounces of gold in reserves at a reserves

GOLD & PGM

will cost you dearly price of $1 500/oz, the highest price among the five companies for the year. It ended 2013 with 104.1 million ounces in reserves, using a reserves price 27% lower at $1 100/oz. After adjustment for depletion and merger-and-acquisition activity, its reserves fell 18% in 2013. The next-highest 2012 reserves price was $1 400/ oz used by Newmont. At $1 300/oz in 2013, its adjusted reserves declined 5% from 2012. Goldcorp’s adjusted reserves declined 15% in 2013 at $1 300/oz, compared with $1 350/ oz in 2012. AngloGold Ashanti’s adjusted reserves declined only 2% in 2013 at $1 100, compared with $1 300/oz in 2012. Kinross, having faced shareholder scrutiny since 2011 over its purchase of Red Back Mining, kept its reserves price at $1 200/ oz for the third consecutive year, but still reported a 12% drop in adjusted reserves in 2013 – with the adjustment including the 2013 write-down of 6.7 million ounces at its Fruta del Norte project in Ecuador, after it failed to reach an agreement with the government on mine development. The remaining decline in Kinross’s reserves was largely due to an increased focus on mining higher-grade ore to reduce costs. So far in 2014, gold prices have been volatile, soaring to $1 385/oz in March at the beginning of the Ukraine crisis, after a three-year low of less than $1 200/oz at the end of 2013, and currently hovering around $1 300/ oz. Although analysts’ 2014 gold-price forecasts

ranged between $1 100/oz and $1 400/ oz, Newmont and Goldcorp used $1 300/oz at the end of 2013 – the most optimistic reserves price among the five majors. “We believe that the majors will likely continue to focus on cost-cutting in 2014

in order to preserve their profit margins, since significant further reserve cuts are unlikely in the near term as companies have already adjusted their strategies to accommodate market uncertainty and investor concerns,” says SNL Metals & Mining’s Nick Wright.

GOLD & PGM

Size counts at Otjikoto The Otjikoto gold project, 300 km north of Windhoek, will be Namibia’s second, and biggest, gold mine when it enters production before year end.

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HE CURRENT MINE plan is based on probable mineral reserves of 29.4 million tonnes, to be mined over an initial 12year period. FLSmidth’s capabilities in the gold extraction arena will be showcased with the supply of equipment to Vancouver-based gold producer B2Gold’s Otjikoto gold project. FLSmidth is the only company in Africa capable of providing a complete end-to-end gold-extraction solution drawn from in-house technology. This know-how and equipment derives from FLSmidth’s Summit Valley range of modular plants and equipment for the extraction of gold and silver. The globally renowned Summit Valley offering includes the industry’s highest capacity

GOLD & PGM

electrowinning cell used in precious metals recovery. The order was placed with FLSmidth in the second quarter of 2013 and comprises 14 Krebs gMAX cyclones, four KC-QS48 Knelson concentrators reporting to a ConSep Acacia CS8000 intense cyanidation reactor, two 20 metre-diameter thickeners (one pre-leach and one tailings) with a bolted tank design, one carbon fines- and one sludge filter, and four electrowinning cells. FLSmidth will provide installation and commissioning supervision on-site, as well as post commissioning support from its Johannesburg operations. FLSmidth’s gMAX cyclones focus on minimising turbulence while maximising tangential velocity, significantly advancing cyclone performance. To achieve these two design criteria, the gMAX incorporates performance-enhancing improvements to the inlet head, cylinder section, cones and apex. The company’s Quantum Series Knelson batch concentrator is highly configurable and uses a rotating assembly, incorporating the latest design in concentrate-cone technology and advancements in the upper and lower frame. “The low-grade Otjikoto ore contains significant gravity gold that can occur in relatively large nuggets, so maximum gravity effort is planned for recovery, with 100% of ball-mill circulating load treated by gravity,” Dave Capstick, FLSmidth business development manager, says. The Krebs cyclones, Knelson concentrators and Acacia leach reactor were

shipped to the mine site in October last year, followed by the filters, with fabrication of the thickeners complete and

These technology solutions are directed at operating customers

TOP Typical FLSmidth electrowinning cells ready for dispatch to site ABOVE Typical FLSmidth electrowinning cell OPPOSITE FLSmidth’s 20 metre-diameter thickener assembly showing the bridge and feed well

trial-assembly underway. The electrowinning cells and standby units are about to be shipped. Since FLSmidth acquired the Utah-based precious metals extraction business of Summit Valley five years ago, it has been actively marketing these products in Africa and achieving a steady penetration of this market. These technology solutions are directed at operating customers who are planning to expand their gold-recovery circuits and those who want to improve their efficiencies, as well as those who are building new plants. There are also significant applications where customers are experiencing operating inefficiencies. In 2013, the company received an order for a complete process flow solution, from elution through to electrowinning, for Shanta Gold’s New Luika Gold Mine in Tanzania. Here, FLSmidth has designed a fully engineered solution to improve the efficiency of its process, together with the addition of an elution, carbon regeneration and electrowinning circuit to the plant. The Summit Valley speciality product range is known worldwide, having been used in 24 countries on six continents over the last 18 years. While this offering incorporates individual components, it also presents world-class capabilities in terms of combining these components into customer specific, integrated gold-room and plant packages. IN SID E M IN IN G 0 7 | 2014 19

GOLD & PGM

Tailings management at Namoya The Namoya mine, situated at the south-western end of the TwangizaNamoya gold belt, covers an area of 174 km² and is expected to double the company’s projected gold production to more than 225 000 oz per year.

OLD WAS FIRST discovered in this area in 1930 and various mining operations have subsequently taken place. A highly effective solution for sub-soil drainage is now in operation at the tailings management facility of a major gold mining project in the Democratic Republic of Congo (DRC). The Namoya site houses a substantial tailings management facility to process the leftover materials and wastewater from the extraction of the gold. It also ensures that any harmful particles do not enter the soil or groundwater. Following a competitive tender, the Ridgidrain twinwall drainage system from Polypipe, a leading UKbased manufacturer of water management and plastic piping systems, was selected to provide effective sub-soil drainage.

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Realising possibilities...

Tailings management is essential for environmentally conscious mining operations Ridgidrain is ideal for non-pressurised and sub-surface drainage applications, with perforations at regular intervals along its full length to allow safe and gradual drainage. Manufactured in high-density polyethylene, Ridgidrain boasts excellent abrasion resistance, internally and externally – protecting against both sediment within the wastewater and the rugged mine environment. It also offers a high compression strength to withstand imposed loadings, yet is still incredibly lightweight for ease of installation and transport. Tailings management facilities are essential in ensuring the mine operates in an environmentally conscious manner, and the Ridgidrain system allows for the controlled seepage of treated water. The system can also deal with unpredictable fluctuations, due to factors such as stormwater, and is a crucial element of an effective water management system. Polypipe supplied 1 386 metres of 500-mm diameter and 190 metres of 600-mm diameter of its Ridgidrain twinwall pipe, shipped via eight 40foot sea containers, which required close coordination between Polypipe’s UK manufacturing operation and the shipping agent in order to meet deadlines and ensure the full order was dispatched as one shipment. Polypipe export sales manager Philip Wood adds: “Plastic piping systems such as Ridgidrain are up to 94% lighter than concrete alternatives, meaning that they are safer to install and move around site, and also offer considerable environmental benefits. Production and transportation are simplified and use less carbon, and additionally the product can often be reused elsewhere when the OPPOSITE TOP The project ends. Namoya gold-mine site in These factors are key conthe DRC siderations for mine operaOPPOSITE BOTTOM Namoya houses a substantial tors, and also make the prodtailings-management facility uct more cost-effective. For TOP Rigidrain protects these reasons, Ridgidrain is against both sediment within growing in popularity in the the wastewater and the rugged mine environment African mining market.”

...from mine to market.

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Tailings & Waste Management

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

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GOLD & PGM

Striking gold at Kibali in DRC

The Democratic Republic of Congo’s Minister of Mines, Martin Kabwelulu, officially opened the Kibali gold mine on behalf of the country’s president, Joseph Kabila Kabange, on 2 May.

HE CEREMONY WAS attended by Province Orientale governor Jean Bamanisa Saidi, DRC cabinet ministers, ambassadors of various countries and local dignitaries. Kibali will rank as one of the largest gold mines in Africa when it is in full production. It is owned by Randgold Resources and AngloGold Ashanti, each with a 45% stake, and the DRC state gold mining company, Société Miniere de Kilo-Moto. Kibali is being operated and developed by Randgold, and represents an investment of more than $2.5 billion by Randgold Resources and AngloGold Ashanti. While still a work in progress, as it is both an operating mine and a development project, Kibali produced 112 549 oz of gold and made a profit from mining, before interest, tax and depreciation, of $86.3 million in the first quarter to 31 March 2014, up 26% on the three months to December 2013, its first production quarter.

Current production Current production is from its opencast mine and an oxide circuit. Commissioning of the sulphide circuit started during the past quarter, while development of the underground mine remains on track, with the vertical shaft reaching the halfway mark and the first underground ore accessed. The first of four hydropower stations is currently being commissioned. With a capacity of 22 MW, it is the largest of its kind in Province Orientale. Speaking at the opening, Minister Kabwelulu said the success TOP (From left) Province Orientale governor Jean Bamanisa Saidi, Randgold chief executive Mark Bristow and DRC Minister of Mines Martin Kabwelulu LEFT Underground at the Kibali gold mine in the DRC OPPOSITE TOP A striking sunrise at the crusher plant

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STRATEGIC PARTNERS SHAFT SINKERS AT KIBALI Shaft Sinkers Holdings has announced that the main shaft at the Kibali gold mine has exceeded 500 m in depth. “The main shaft-sinking is progressing very well, and has reached the major milestone of 500 m, with sinking proceeding at a rate of at least 3 m/day for more than 30 continuous days,” says CEO Alon Davidov. The South Africa-headquartered and London-quoted specialist shaftsinking contractor has updated its progress on the project, which is ramping up to be one of Africa’s largest gold mining operations.

When we all work together “Here we have shown what can be achieved in Africa when we all work together: a government that understands the importance of attracting and retaining the investments that are necessary to build a modern economy; two mining companies that believe in sharing the value they create with all their stakeholders, especially the local community; a labour force that is eager to grasp the opportunity of working and learning; and a people who have welcomed us and supported our endeavours.” Randgold chief executive Mark Bristow said at the opening that the successful development of Kibali could herald the birth of a new DRC economic region to rival Katanga Province. “To achieve that, we cannot rest here. We need to ensure that we deliver the returns expected by the investors who entrusted us with their money. We have to run a profitable mine, focused on long-term viability, that pays taxes, and employs and develops citizens

from this region and this country. “Kibali must become the catalyst that triggers the additional investment required to grow a strong regional economy. Wishful thinking will not make this happen. However, if we continue to work together as partners pursuing a common goal – if mining companies, the government and communities cooperate as we did in the development of Kibali – then this dream of greater things will also come true.”

DRC mining code AngloGold Ashanti chief executive, Srinivasan Venkatakrishnan said that, for Kibali’s full potential to be realised, it was of the utmost importance that the DRC’s mining code remained supportive of the gold mining sector. “The government now has an important opportunity to show the world that it is welcoming of gold mining by helping to create what can in a short time become one of the largest gold producers in the world and an engine of growth for this region and this country.” At Kibali, total reserves now stand at 11.6 million ounces at 4 g/t, up from 10.9 million ounces at 4.1 g/t, as a result of an updated mine design on a resource base that grew to 22 million ounces. While current reserves support a 13-year life of mine, only 53% of the current resource has been converted to reserves, leaving a significant opportunity to expand the reserves. In just eight years, Randgold has grown from its exploration roots through openpit mining to become one of Africa’s leading underground miners, with two worldclass mines in Yalea and Gara, a third being developed at Kibali and a fourth at feasibility stage at Gounkoto. I N S I D E M IN IN G 0 7 | 2 0 1 4 23

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of the investment was a testimony to the world that the DRC government was determined to support investors and see its mining sector developed. “Orientale now boasts a worldclass operation, and there is no doubt many economic activities will follow as a spin-off of what Kibali is achieving. The people of Orientale need to protect this significant investment zealously.” Also speaking at the opening, Randgold chairman Philippe Liétard said the successful development of Kibali in the face of many infrastructural and other challenges was a triumph for the company’s partnership philosophy.

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GOLD & PGM

Impala Opencast finally complete One of the longest-running opencast mining contracts in recent company history has now been completed by Concor Opencast Mining.

HE IMPALA OPENCAST project, located on the western limb of the Bushveld Complex near Rustenburg, was awarded, in 2002, by Impala Platinum and mining commenced in the vicinity of Impala #6 shaft, with the Concor Opencast Mining team tackling the Merenksy ore body first. In 2005, the team began mining the UG2 ore body. The two Merensky faces were relatively small-scale, while the UG2 was present

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on a much larger scale, with seven faces mined. These reefs ranged over a 9 km area and were mined to a depth of 35 metres. Lower down, the Impala Platinum underground operation mined ore from its shaft systems. The opencast contract included crushing the material to <300 mm and its delivery to the mine’s stockpile, as well as rehabilitation of mined areas. Since 2002, the contact was renewed on an annual basis until all opencast resources

were depleted. Between November 2009 and December 2013, Concor Opencast Mining mined 49 340 574 bm3 of blasted overburden, 6 576 454 bm3 of topsoil and 8 871 767 tonnes of reef. “This project was tightly controlled throughout its duration to mitigate the associated challenges,” Roger Hearne, acting general manager of Concor Opencast Mining, says. “For example, mining took place in close proximity to both mine infrastructure and housing occupied by members of the local community. Great care had to be taken not to impact these structures and we achieved this by keeping the vibration from blasting to a minimum. In addition, blasting was only carried out twice a week, out of consideration for the local communities. “At all times, we also had to be careful not to hole through to the mine’s underground workings. For this, we depended on existing surveys and worked closely with the mine surveyor to ensure that highwall positions were correct.” At the end of the project, the team had achieved more than five million fatality free hours – 1 196 LTI-free days, TOP Cleaning top of reef at Impala Platinum BELOW Topsoil rehabilitation at Impala Platinum Pit 9 South OPPOSITE Overview of the opencast pit at Impala Platinum

GOLD & PGM

Concor Opencast Mining applied the strip-mining method, with average advances of 30 metres wide. The team was also responsible for the complete drilling and blasting operation in all pits. The ore body was exposed, extracted and transported to a rail siding 5 km away, where it was crushed and transported by rail to the plant for further processing. Haul-road maintenance was critical to minimise wear and tear on vehicles and ensure safety. Throughout the project, Concor Opencast Mining maintained an active presence in the mineâ&#x20AC;&#x2122;s local communities. The Concor Orphan Project was introduced in 2008, revolving primarily around the delivery of food parcels to the three primary schools closest to the project site. The company also employed a local, emerging sub-contracting company, which it mentored to successfully undertake the required top-soil rehabilitation. Personnel were trained in production methodology, on how to achieve targets, on costing and on safety issues.

overburden and top soil, 25 trucks onearning several Impala Platinum and site, three water carts and various ancilConcor Opencast Mining safety awards lary support plant. A static jaw crusher along the way. Hearne says this remarkserviced the southern pits during the able achievement can be attributed to project, while a mobile jaw crusher serthe Murray & Roberts STOP.THINK. viced the northern pits. ACT 24/7 safety programme, together with the Bill of Rights and life-savingÂ rules. â&#x20AC;&#x153;This project was tightly Weekly safety audits were controlled throughout its carried out by Concor Opencast Mining, while Impala duration to mitigate the Platinum undertook 40-day associated challenges.â&#x20AC;? safety audits. Visible felt leadership was also part of the safety environment, aimed at influencing and transforming behaviour. A total of 240 people worked on the 15 km project site. Equipment comprised five bulk excavators for overburden removal, six smaller excavators for cleaning and extraction of the ore body, five dozers for moving

IN SID E M IN IN G 0 7 | 2014 25

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INFRASTRUCTURE

A fresh approach in T

The interface between mining and infrastructure is a key focus of newly formed Murray & Roberts Infrastructure. Gerhard Hope talks exclusively to managing director Eric Wisse.

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HE INTEGRATION OF the Concor Civils and Concor Roads & Earthworks divisions of Murray & Roberts into a new division known as Murray & Roberts Infrastructure is bound to shake up the infrastructure market locally and further afield, sending a strong message that South African players are keen on applying their skills and expertise to the current infrastructure deficit. “Especially where infrastructure and mining come together – that is where we find we have been quite successful in the past,” says Wisse, former managing director of Concor Roads & Earthworks. “Traditionally, we have been quite good at initiating projects. We are normally the first on-site. There is a benefit being in that space, especially going into Africa and following a major mining client.” A major focus in the South African mining industry at the moment is social housing initiatives associated with major housing projects. “We have looked at a couple of those,” confirms Wisse. “What is of particular interest to us is the infrastructure associated with such housing projects, from sewerage to roads and water.”

INFRASTRUCTURE

Africa Distinct advantage Such an emphasis on corporate social responsibility and investment is a characteristic of the South African infrastructure market that gives local players a distinct advantage into venturing further afield into the region. “We understand the market very well, which attracts a lot of social investment,” says Wisse. This is in addition to the general empowerment criteria that need to be adhered to. While Wisse describes the current market conditions as “tough”, he notes that “in the last couple of months we have seen quite a bit of tender activity, which is a good sign. I think we are positive that bulk infrastructure projects will start happening. From roads and dams to bulk water projects and rail, there is going to be a lot of action.” Wisse explains the reasoning behind the establishment of the new division: “First of all, it was to create a new identity within the Murray & Roberts group, and then to create some clarity in terms of its infrastructure focus, as we were operating under the old Concor names.”

from July,” notes Wisse. He adds that the team has already been relocated in its combined offices, and is rearing to go. “Our major competitive advantage is leveraging the lower cost base, and providing a single point of contact for all civil infrastructure work, as well as a single Murray & Roberts brand for infrastructure.” The integration has proceeded with remarkable speed, which is a testament to the group’s internal structure and processes. “It was mainly the head office structure that was affected; the operations were largely unaffected, and are carrying on as

“Having regional offices in Africa gives us a good footing to work from.” Eric Wisse, MD, Murray & Roberts Infrastructure usual. It is about engaging with all stakeholders, and ensuring that everybody understands the reason behind it, and why it makes business sense. “The challenge going forward is to develop a new culture that takes the positives from both divisions, and to take that forward. Having a single entity that deals with all infrastructure projects makes it easier for clients to comprehend.”

Resultant synergies In terms of the benefits, Wisse points to the resultant synergies. “It also creates savings on overheads so there is a lower cost base. I think there was also quite a bit of overlap in capacities. Both companies did similar work to a certain extent, and that duplication has been taken out now.” The integration process was embarked upon in March, and has been largely completed. “We are closing the financial year at the end of June in the separate divisions and will report as the new integrated division

permanent presence in both Namibia and Botswana, with ongoing projects in both. “A big focus is the oil and gas industry in East Africa.” Wisse adds that the regional offices in Mozambique, Zambia and Ghana will be leveraged to bolster the group’s capabilities and reach in this area. “In the mining industry, both companies have done much work in mining infrastructure for various clients in iron ore, platinum, gold and coal. That remains a focus. We continue to assess opportunities in Africa. I think we have got a bit more of a focused approach now. We have identified certain parts of the industry and certain parts of Africa where our real

Presence in Africa Wisse explains that Murray & Roberts Infrastructure falls under the Murray & Roberts Construction Africa and Middle East platform of the Murray & Roberts Group. Looking at Africa, the group has a

focus lies, but wherever there is a real opportunity, we will look at it. I think we are flexible enough, and having those regional offices in Africa as well gives us good footing to work from,” says Wisse. Murray & Roberts Infrastructure will focus on the full civil spectrum, from water to roads, rail and power stations. It is also involved in the burgeoning renewable energy sector, having just completed a windfarm project in Jeffreys Bay. “We are looking into solar energy and hydroelectric opportunities as well,” confirms Wisse. “That could provide some good base-load work over the foreseeable future. I think we are positioned quite nicely, with our base of diversified experience.”

OPPOSITE TOP Murray & Roberts Infrastructure’s scope of work for the project included the construction of 60 concrete foundations for the wind turbines OPPOSITE Earthworks in progress at the local siding and the main access road on the Kolomela contract in the Northern Cape RIGHT Rapid progress was made by the company on the multi-million rand contract at Transnet Capital Projects’ City Deep Container Terminal which included the construction of new concrete paving, civil services and electrical lighting

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INFRASTRUCTURE

Dingleton on the move Kwikspace has successfully completed numerous large-scale accommodation projects throughout sub-Saharan Africa

efficient move takes place, also considering the housing needs of the construction team involved, building solutions that are speedily completed are essential to the success thereof. Having successfully completed numerous large-scale accommodation projects throughout sub-Saharan Africa, Kwikspace has earned its reputation as a reliable and highly competent supplier of rapidly deployed buildings and thus was contracted to supply prefabricated housing in Kathu for the construction team involved with the town relocation. Kwikspace is thus currently involved with the erection of a 1 000 person camp, which includes the supply of 129 prefabA province rich in minerals and profitable ricated accommodation units, as well as a kitchen and diner measuring 1 464 m², investment opportunities, the Northern Cape is a mobile recreation building measuring 164 m², 20 change rooms and ablution seeing mining developments gain ground both units and two site offices measuring 141 literally and figuratively. m² each. The prefab housing project was initiated in mid-March and Kwikspace anticipates completion of the camp by the end of June 2014. N FACT, in order to further expand allow for mining in the buffer zone, that Due to the robust nature of Kwikspace’s on the mining industry at present, an the community is being relocated to the products, which are manufactured using entire town situated within this provNorthern Cape town of Kathu, approxipolyurethane panels, the construction ince’s borders is being relocated to almately 30 km away. team can look forward to comfortable aclow for such expansion. Making a remarkFurther supporting the reasoning becommodation as temperatures are excelable contribution to this process is Africa’s hind the relocation is that residents’ qualilently controlled, noise is reduced and the leading manufacturer of prefabricated ty of life was negatively affected due to the ingress of dust, buildings, Kwikspace Modular Buildings. proximity of the water and insects The town, formerly known as Sishen, mining activity. “We fortunately is prevented. was renamed Dingleton in 1990 and was In addition, inRoberto Camoriginally established in the early 1950s vestment in the have over 40 years’ pos, sales execto accommodate local miners working at town subsided experience on our side.” utive for KwikSishen mine – a large iron mine, which as the prospect space Modular represents one of the largest iron ore reof resettlement Buildings, comments: “Although this is serves in the country. had originally been put on the table over a massive project, we fortunately have Although the area has significant po20 years ago. Following this, businesses over 40 years’ experience on our side, tential for further iron ore mining, it has vacated the area, leaving little room for which makes the magnitude thereof been limited by the fact that the town growth potential apart from mining. less daunting and more exciting. We are of Dingleton is situated a mere 500 m The processes, which have been followed confident that our contribution to this away from the mine’s opencast boundary, in order to reach the point of relocation, project will have a positive impact on which is the minimum required blasting have been extensive and have involved the development of the mining industry distance from human settlements accordinput from the community. Now that in this area.” ing to legislation. It is for this reason, to the ball is rolling and to ensure the most

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INFRASTRUCTURE

Huge fans of Maseve The project calls for one bifurcated and one trifurcated main fan station, incorporating two and three axial flow fans respectively, powered by 315 kW motors

BBE Projects has clinched an order for additional fan stations at Platinum Group Metals’ (PTM) Maseve project, being built by the Western Bushveld Joint Venture (WBJV).

HIS FOLLOWS THE successful commissioning of two surface main fan stations delivered on a turnkey basis at the end of 2013. BBE Projects is a division of consulting engineering company Bluhm Burton Engineering. The team is on track to commission the new fan stations in January 2015. The second order is identical to the first, calling for one bifurcated and one trifurcated main fan station, incorporating two and three axial flow fans respectively, powered by 315 kW motors. As with the first order, the scope includes all structural, mechanical and electrical engineering design and specifications, all steel ducting, buildings, fan mechanicals, electric drives, instrumentation and control systems, as well as construction of the raise bore ventilation shaft collars and application of ground stabilisation around each collar. Formal construction of the WBJV Project 1 platinum mine – a shallow, high-grade deposit – began in 2010. First production through the North twin decline system is scheduled to ramp up through 2015, with

a targeted full 20-month ramp up to 160 000 tpm run-of-mine nameplate capacity. Two identical twin declines with immediate access to high-grade ore are necessary to extract the most flexibility and value from the ore body.

DRA is EPCM contractor In collaboration with DRA, the primary EPCM contractor for the mine’s surface development, BBE Projects has planned the construction of the surface main fan stations in such a way that several tasks are executed simultaneously, ensuring the best possible delivery date. Environmental issues needing particular attention on these projects include mitigating the impact of noise and dust on the local farming community. Power during construction is being provided by on-site generators. “BBE Projects has forged an excellent long-term relationship with DRA through our consultancy work, and we are delighted to be working alongside them on turnkey projects for the first time,” says BBE

Projects managing director Richard Gundersen. “This further entrenches our total fan station capability in the market place, and builds on other successful turnkey projects executed for major platinum and coal clients.”

Turnkey service BBE Projects was created in response to increasing client demand for a full-spectrum turnkey contracting service in the field of mine ventilation, refrigeration and cooling. Its team comprises mechanical, electrical, civil, process and project engineers, with experience gained in the world’s deepest mines, across a range of commodities, supported by draughting, finance and administration personnel. BBE Projects focuses specifically on delivering complete and turnkey systems to mining sector clients. The company is structured to deliver turnkey projects incorporating the design, supply, construction, commissioning and process performance guarantee of complete surface and underground ventilation, refrigeration and cooling systems. Particular areas of expertise include refrigeration and air cooling stations, energy saving schemes, thermal storage installations, main fan control and monitoring systems. All manner of projects are undertaken, from greenfield sites to plant extensions and upgrades. Being totally independent, BBE Projects is able to offer the optimal solution using the best combination of selected equipment from a variety of suppliers. IN SID E M IN IN G 0 7 | 2014 29

Dust Suppression Water Purification

ENVIRONMENTAL

Environmental Services Fire Solutions

+27 (0)12 349 1441 www.i-cat.co.za info@i-cat.co.za

INFRASTRUCTURE

1 200 tonne trusses at Sentinel copper mine Vanguard, South Africa’s heavy-lift specialist, has just completed its heaviest strand-jacking lift to date. The heaviest lift of its type ever done in the region.

The project was made more challenging by the extreme tolerances needed to be able to fit the conveyor sections

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WO PREFABRICATED conMay by Vanguard’s six-member, on-site veyor trusses in excess of team. Ron Wiggill, Vanguard’s heavy-lift 1 200 tonnes each have been engineer and senior project manager for lifted from their assembly pothe operation, explains: “In conjunction sition at ground level to their working with First Quantum’s projects office in position at a height of approximately 50 Australia, we had – prior to the start of m above the ground. the on-site works – been involved in the The conveyors form part of the new design of the system for almost one year. plant currently being constructed by “In addition to the huge weight, the First Quantum Minerals at its Sentinel project was made more challenging by copper mine site near Mwinilunga in the extreme tolerances to which we had north-west Zambia. to work and fit the conveyor sections,” Using four 418 tonne strand jacks with says Wiggill. an integrated computer control system, the two conveyor trusses ABOUT THE COMPANY (one 80 m and the other 67 m in Vanguard is a South African company specialising in the transport, lifting, placing length) were hoisted in a ‘synchroand assembly of heavy plant across all nised lift’ into position. industries. Vanguard was established 40 Each lift took less than a week years ago and completed its first strandto complete, and the project was jack lift in 2005. successfully completed in early

INFRASTRUCTURE

Mining firms head north The action in the mining industry is moving north, with the next ore bodies to be exploited located beyond SA’s borders.

GAINST A BACKDROP of waning investor appetite Roberts Cementation Training Academy at Bentley Park, near in the South African mining industry, Murray & RobCarletonville. This Mining Qualifications Authority-accredited erts Cementation has set its sights on realising the pofacility is unique in the contracting space, giving our personnel tential for growth it has identified in the greater Afrithe matchless opportunity to learn best-practice mining and can market. This focus has led to a formal African growth strategy that has already “With the downturn in W Australia, seen a pleasing growth in the company’s order book from African operations, the competition for African projects which currently constitutes about 25% of from Australia has increased.” its turnover. Chris Sheppard, MD, Murray & Roberts Cementation “With the action in the mining industry moving north and the next ore bodies to be exploited located in other African countries, we initishaft-sinking skills by working on full-scale mock-ups and simated a study to evaluate the potential in these countries,” Chris ulators. They acquire these skills in a controlled environment Sheppard, managing director of Murray & Roberts Cementafree of noise, environmental hostility or the pressure of protion, says. “This involved gaining an understanding of the risk, duction targets. logistical constraints and potential clients in each country and has resulted in a hub-and-spoke strategy that we believe will steadily grow our business on the continent. “In recent times we’ve established representative offices in Ghana to serve clients in West Africa and in Zambia as a Central African base, as well as an office in Maputo, Mozambique, in anticipation of significant infrastructure work expected to flow from the coal-mining industry in the Tete province. It’s satisfying to see that we already have three major projects in Zambia, while we are actively seeking work in the DRC, having secured an in-country partner to identify potential underground mining projects. At the same time, we’re targeting prospects in Ghana and Mauritania.” Sheppard adds that Murray & Roberts Cementation differentiates itself through its ability to enter into internal joint ventures with international sister companies in the Murray & Roberts Group, notably in Australia and Canada, to add real value to projects. For example, the company is poised to engage with a project in Mauritania in JV with Cementation Canada, which, among other resources, has provided the necessary key personnel proficient in French. “With the downturn in mining in Western Australia, the competition for African projects from Australia has increased, while China is also making its presence felt on the continent,” he continues. “With access to trackless mining expertise from our sister company in Australia, Murray & Roberts Cementation is, however, well able to compete by adding an Australian flavour to our African bids, while our competitive edge against the Chinese lies on the quality side of the equation. Access to our group’s Global Underground Mining Platform provides us with world-leading shaft-sinking skills out of Canada. “We are also differentiated by the Murray & I N S I D E M I N I N G 0 7 | 2 0 1 4 31

INFRASTRUCTURE

Complete solution for emergency vehicles

IRE TRUCKS 4 Africa and Ambulances 4 Export are two companies with one business concept in mind: to provide a complete solution for supplying emergency vehicles and equipment anywhere in Africa and elsewhere. The two companies have over 30 years’ experience in Africa, and have supplied new and pre-owned emergency vehicles to mines and industry all over the continent. With offices in South Africa and premises in the UK, they are in a good position to provide a solution to any emergency management requirements.

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New fire trucks are built on most European chassis, including Mercedes, Scania, MAN and Iveco. It can supply anything from fast response vehicles to 8 x 8 heavy-duty firefighting vehicles. Preowned vehicles are sourced from the UK fire brigade and military-replacement programmes. All are tested and checked prior to export. Most makes can be converted to left-hand drive if required. New right-hand drive ambulances are built and supplied from the Cape Town factory. New left-hand drive ambulances are available and can be built to specification. Pre-owned ambulances are

available from the UK for right-hand drive and from Germany for left-hand drive vehicles. EQUIPMENT AVAILABLE • Fire trucks • airport crash tenders • ambulances • ex-military vehicles • 4 x 4s and all-terrain vehicles • fire-fighting equipment • rescue equipment • plant and equipment • airport equipment • protective clothing.

INFRASTRUCTURE

Altaaqa Global in Africa

UBAI-BASED ALTAAQA Global Cat Rental Power, a global provider of temporary power solutions, has recently opened a branch in Nairobi, Kenya to serve the East Africa territory. The new office will cater to several countries, including Tanzania, Rwanda, Burundi, Uganda, Kenya, Somalia, Ethiopia, Sudan, South Sudan, Djibouti and Eritrea. Peter den Boogert, general manager of Altaaqa Global, says: “Business activities in the East Africa region are flourishing, with its economies thriving in recent years, resulting in an increased demand for power. “At Altaaqa Global, our aim is to be on the ground as quickly as possible when customers require our energy solutions.

Our new branch will enable us to reach this region faster than before. We realise that our industry is driven by emergency needs and hard deadlines, but uses equipment that requires substantial lead times to acquire,” says Den Boogert. “With the combined fleet of our sister company in Saudi Arabia, Altaaqa Global has about 1 400 MW of rental power readily available so that we can focus our efforts on rapid deployment and customer satisfaction.” Steven Meyrick, board representative of Altaaqa Global, commentes: “This strategic expansion is in line with our vision to be the leading and the most preferred temporary power solutions provider before 2020. During our geographic expansion, we will continue to heavily invest in human

resources, further improve our business processes, and expand and diversify our fleet of Cat power generators. “We now have the capability to provide power plants running on various fuel, such as piped natural gas (PNG), liquefied petroleum gas (LPG), compressed natural gas (CNG), liquefied natural gas (LNG), flare gas, diesel, dual-fuel (70% gas and 30% diesel), and, very soon, heavy fuel oil (HFO),” says Meyrick. “East Africa has a promising economic outlook within the energy and engineering sectors,” says Majid Zahid, strategic accounts director of Altaaqa Global. Majid Zahid says in conclusion: “We are delighted to open our new office to provide interim power plants ranging in size and with the latest technology in power generation.”

IN SID E M IN IN G 0 7 | 2014 33

INFRASTRUCTURE

At the top E of its game From work at Eskom’s Medupi and Kusile power stations to a new smokestack at Syama in Mali, Skyriders is constantly and literally at the top of its game. By Gerhard Hope

STABLISHED IN 1999, Skyriders has built up a solid reputation for work-at-height solutions, rope-access aided inspection and non-destructive testing (NDT). “Basically we do absolutely anything off a rope, as opposed to using scaffolding, cranes or man baskets,” says marketing manager Mike Zinn. This ranges from basic to specialist maintenance to welding, the application of corrosion and other protective coatings, rigging and bolting. “We are in the process of building up our NDT inspection side,” confirms Zinn, explaining that a new inspection manager was recruited in June, whose main focus will be to drive this segment of the business for major customers such as Sasol and Eskom. “We already do a lot of inspections for them, but if we can do more it will be beneficial to us.” The mining industry itself is a major growth area for Skyriders, from installing lifelines at Anglo Coal’s Isibonelo colliery to smokestack maintenance for Palabora Mining Company in Phalaborwa. “There is definitely major potential in the rest of Africa.” Zinn adds that the current mining

LEFT Skyriders has garnered considerable expertise over 15 years BELOW Skyriders prides itself on the skills and accreditation of its workers OPPOSITE FROM TOP Skyriders will do absolutely anything off of a rope A cooling-tower inspection underway A common misconception surrounding rope access is that it is a hazardous and uncontrolled work practice

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INFRASTRUCTURE

market has allowed the company to offer its broad client base “a good alternative in times of recession.” A key example of this is utilising Skyriders’ specialist services to slash costs on scaffolding, where “often it is a case of building a R120 000 scaffold tower to carry out a R10 000 project.”

Safe, cost-effective solution Zinn says the idea is to promote rope access as a safe, reliable and cost-effective solution. “We have garnered considerable expertise and experience over the last 15 years. It is incredibly safe. The Institute for Work at Height has now officially adopted the ISO standards for rope access, which means that the old SANS standards have now been superseded.” Skyriders prides itself on its experience and accreditation, with most of its project managers boasting a Level 3 classification, which is the highest rope-access qualification attainable in South Africa. Level 1 is a six-day course, comprising both theory and practical, ranging from basic self-rescue manoeuvres to ascending and descending and transferring from one rope to another. A candidate is only allowed to apply for Level 2 after having completed 1 000 hours, which has to be verified by a Level 3 technician. “Level 3 is quite complex, comprising advanced topics such as aerial ropeways, intricate rigging and pulley systems, and complex rescues.” Zinn says that Level 3 technicians have sole responsibility for all rope-access operations on-site. “Mining is definitely an area where we would like to grow. It is a difficult market, from the point of view that the mines have done things their way for a long time, and generally have the impression that rope access is dangerous, which it is definitely not.” Zinn explains that Skyriders has a long-term strategy for the mining industry. “That was our first major large-scale mining project, helping them inspect and get rid of build-up in the raw ore mineral silos. Basically our services come into play wherever there is work at height or confined spaces. It does not even have to be that high, just be high enough to warrant scaffolding, with our service able to beat the time delays associated with erecting and dismantling that scaffolding,” explains Zinn. In terms of its scope of services for Eskom, this mainly involves inspection of the coal bunkers or silos. “Eskom usually has a very narrow window to carry out

these types of maintenance inspections before they need to replenish the coal bunker or silo again, in order to continue feeding the power station. What this means is that essentially before the first three decks of scaffolding can be erected, we are already finished with our inspection,” says Zinn. The rope-access sector is divided into a highly competitive commercial sphere, from painting to window washing, building wraps and advertising hoardings, to the more specialised industrial side, which itself has a further highly advanced niche in terms of the offshore oil and gas sector. “They do all sorts of tasks on floating platforms and rigs.”

Medupi and Kusile Zinn confirms that Skyriders has teams at both Medupi and Kusile, who are carrying out a range of tasks, from installing safety systems to rigging, bolting and torque verification, painting and inspection. “A lot of the work that we do at Medupi and Kusile involves assisting non-rope-access, qualified riggers from other companies in positioning their rigging equipment so that they can rig and move ducting, piping and steelwork into place,” he explains. Looking at current projects, the company is about to undertake a welding contract at Mittal in Newcastle. “This work will be a challenge, as it will be the first time it will ever have been done this way. However, we are confident that our approach will work and open doors for us,” comments Zinn. He points to the new smokestack for the Syama gold mine in Mali, completed in July 2013. Skyriders was contracted originally in 2009 by Resolute Mining of Australia to carry out inspections and maintenance-related repairs on another smokestack.

The latest project required the company to assist in building the new smokestack from scratch, which entailed a seven-man team bolting the components together, and adding ladders and platforms as the smokestack progressed vertically. In Mali, the client was unable to mobilise a crane to lift the smokestack components, so a system was designed and engineered to accomplish this in sections. IN SID E M IN IN G 0 7 | 2014 35

HEALTH & SAFETY

New paradigm A trend in mining is the use of biometrics to control access to earthmoving, blasting and other mining equipment. Managing director Anton Lourens tells Gerhard Hope how Booyco Electronics is pioneering such developments.

OOYCO’S BIOMETRIC key unit is the ideal solution where controlled access to moveable items, such as earthmoving and mining equipment, blasting boxes and carts, as well as conveyor starter panels and sub-stations, is essential. It eliminates the injudicious borrowing of keys or access cards, thereby limiting access to sensitive and critical equipment. The system requires dual verification through a smart card containing the user’s detailed information and fingerprint scanning. When the user presents his fingerprint to the reader, he is requested to present his card to the key unit. Only once the user’s identity and credentials have been authenticated, will they be permitted to open up boxes or start-up equipment.

seamless communication with computers and networks, allowing the rapid download of data for analysis. Up to 100 000 access registrations can be stored on the system before downloading to a PC is required, making it ideal for deployment on remote sites. “The use of the Booyco biometric key unit on mine sites will result in enhanced control and accessibility to equipment that requires careful management. In addition to its obvious usefulness in protecting moveable equipment, we anticipate that the system will be adopted underground in other control environments, such as explosive magazines and underground substations,” says Lourens. The company is active throughout the mining industry, with customers from

“The use of the Booyco biometric key unit on mine sites will result in enhanced control of accessibility to equipment that requires careful management.” Anton Lourens, managing director, Booyco Information such as the user’s red ticket, vehicle licence, induction certification and other work-related credentials are stored on a MIFARE proximity card. Should any of this information be invalid due to expiry of certificates or possible suspensions, he will not be permitted to access the specific equipment. In addition, such a registration failure, together with other access data captured during log-in transactions, will be stored on the system for future downloading.

Tamper-proof system The tamper-proof system is housed in a robust metallic case. With an IP54 rating, it is suited to harsh mining conditions, with an intrinsically safe unit available for use in hazardous areas. An Ethernet connection provides fast and Booyco Electronics biometric control system

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Rustenburg (platinum) to Witbank (coal) and the Free State (gold). “We have been very fortunate to have such a range of customers,” says Lourens, adding that not only has it deepened Booyco’s market penetration, but it has allowed it to remain flexible in responding to diverse customer needs.

Core focus “Our core focus is electronic safety equipment. We do not supply run-of-the-mill products such as roof bolts or personal protection equipment. What we often find is that our customers drive us into specific product areas, such as our current innovation of biometric key control. A concern for the mining industry at present is unlicensed people operating machinery, due to the health and safety implications,” says Lourens. Booyco’s client list includes the top mining houses in South Africa, from Anglo

American to Rio Tinto. It is these major players who are highly receptive to innovation and technology. The company was established originally in 2006 to supply collision warning equipment for Anglo American’s thermal coal division. “The particular product we support has actually been designed and manufactured in collaboration between South Africa and Germany. We are currently in our fourth generation of equipment. It has been implemented quite successfully.” Lourens says that Booyco remains a proudly South African company, and has subsequently designed a range of local products, focusing on telemetry, gas detection and environmental monitoring, which it believes are quite critical in the mining industry. The company currently employs 150 staff, and is ISO 9001 accredited.

Commitment to innovation “Our biggest customer contact base on a person-to-person level is the engineering staff, as they are often the first to come into contact with problems on the ground in need of specific solutions. Our approach is that if one customer experiences a particular problem, then the probability is quite high that the next customer will encounter a similar problem. We are really committed to innovation in this regard. We spend quite a big portion of our annual turnover and profit on R&D and continuous product improvement,” says Lourens. Booyco also plays a vital role in promoting best practice in terms of health and safety in the mining industry. With new legislation imminent in respect of collision warning systems in particular, Lourens notes that more and more vendors have entered the market in the hope of being able to supply products. “We have seen a lot of new entrants from Australia, the US and Germany. As far as that is concerned, South Africa is definitely leading the way globally, in terms of intervention in a possible incident between operator and machine.” Booyco’s development of collision-warning systems is also dovetailing with the general trend in the mining industry to opt for increased mechanisation, automation and control.

Groundbreaking R&D Lourens comments that the work being done by Booyco at the moment in this regard “is fairly groundbreaking,” and has made the local mining industry sit up and take notice. “The mining industry does not necessarily want to trial new technology due to the cost and production implications; they prefer instead to appoint a solutions provider.” This is where Booyco comes into its own, as it forms a vital bridge between OEM equipment and total systems. “Our approach with the collision-warning systems has always been to be able to adapt the same equipment for multiple functions, such as for proper access control, for example. Obviously cost is a major driver here, as mining houses do not want to double up on unnecessary technology. Ultimately we are seeing a trend for single, multifunction solutions from a dedicated technology and service provider such as ourselves. We are really committed to offering comprehensive one-stop solutions,” says Lourens. I N S I D E M I N I N G 0 7 | 2 0 1 4 37

COLLISION WARNING SYSTEMS INTRINSICALLY SAFE SOLUTIONS INDUSTRIAL NETWORKING, TELEMETRY, MONITORING AND CONTROL SOLUTIONS ENVIRONMENTAL SENSORING INSTRUMENTS ASSET MANAGEMENT AND SOLUTIONS

THE MINING INDUSTRY TRUSTS BOOYCO ELECTRONICS TO PUT IT ALL TOGETHER! 0861 BOOYCO (0861 266926)

+2711 823 6842 • www.booyco-electronics.co.za

HEALTH & SAFETY

Illuminating the way A first-of-its-kind Luminator cap lamp, set to eliminate the hazards of reduced visibility in South African underground mining operations, has officially been launched by MSA Africa.

HE sub-Saharan sales leader for MSA, José Peral notes that the Luminator sets itself apart from all other cap lamps in the world, as it features a number of groundbreaking innovations set to dramatically improve visibility and personal safety for South African underground miners. “A major feature is that it enhances the miner’s ability to more effectively detect cracks on hanging walls, which usually represent signs of ground falls and roof collapse. By swiftly identifying these cracks, miners save valuable seconds and are able to evacuate in the event of a rock fall,” says Peral. This improved visibility is made possible by two state-of-the-art LEDs. The working beam is emitted by an OSLON SSL 150 high-class LED and works through an internal reflection and refraction lens, which creates homogenous and halo-free light. In combination with its colour temperature, identifying cracks on hanging walls or seam layers is simplified with the MSA Luminator cap.

Functionality button An easy-to-find functionality button allows the user to switch between three modes, namely; working light narrow beam, peripheral light and walking light. “The extended walking light illuminates the two-step walking distance in front of the user, which increases the worker’s comfort and underground safety by reducing injuries caused by tripping or slipping due to insufficient light,” says MSA Africa product manager Tshepo Lebona. The Luminator cap lamp also boasts MSA’s LiFePO 4 lithium-ion battery pack technology, which ensures that working light is able to run for more than 36 hours, well above the industry average of 24

hours. It also provides an additional 100 hours of emergency light, which is essential, as trapped miners are provided with sufficient light to make their way to a safe area to await rescue. The LiFePO 4 battery pack is protected against deep discharge and has a life cycle of 1 000 discharge and charge cycles, with the battery capacity maintaining up to 80 per cent nominal capacity. A Luminator cap lamp that has been used for a 12-hour shift can be recharged within four hours, while a fully flat battery can be recharged within ten hours.

Cable management solution The MSA Luminator cap lamp also features a world-first cable management solution that can be adjusted easily between 1 m and 1.6 m to minimise the risk of hooking on obstacles that may cause serious injury to the miner. The headpiece weighs only 160 g for extended wearer comfort. The MSA Luminator cap lamp can be clipped easily onto any type of hardhat, and each unit comes standard with a radio frequency identification tag that can be used for asset control. The positioning also allows for enough clearance to attach earmuffs to the helmet, if necessary.

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We get you home safely

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HEALTH & SAFETY

Mining suppliers beware

INING EQUIPMENT providers can be held liable for damages in the event of an accident occurring in a mine where insufficient information was supplied by the company on the safe use of machinery, or if instructions were incorrect or equipment supplied is found to be unsafe. It remains the onus of the equipment supplier to ensure documentation and instructions on the safe use of the equipment are presented to the mine at handover and that all paperwork is correct. Similarly, suppliers of custom-made or complex machinery, where no instructions are available, need to ensure the necessary on-site training is supplied and that operators are sufficiently trained to ensure the equipment can be safely used.

This is a potential pitfall for scores of smaller suppliers who supply customised and one-off type machines to the mines without due consideration being paid to the Mine Health and Safety Act (MHSA). Speaking at a recent Aggregate and Sand Producers Association of Southern Africa (Aspasa) workshop, legal expert Cecil Naude said that all companies within the mining supply chain need to pay attention to their obligations according to the act.

Safety first â&#x20AC;&#x153;Section 21 Act 29 of 1996 states that any person who supplies any article for use at a mine must ensure that it is safe and without risk to the health and safety of workers when used properly. In the case of equipment being resold by a third party supplier (reseller), the manufacturer

importer, designer and so on. is absolved of responsibility if they have informed the reseller and taken specific steps to ensure (as far as possible) that the item is safe and without risk to health and safety when used properly and that it complies with all prescribed requirements.â&#x20AC;? Naude concluded that mining companies and suppliers alike need to be aware of stipulations in the MHSA and take the necessary steps to ensure compliance. Alternatively they run the risk of prosecution or civil litigation in the event of loss of property or earnings of life as a result on non-compliance or negligence. Aspasa is working with authorities and role-players to ensure compliance with legal and statutory requirements of its members and affiliated companies, according to Naude.

IN SID E M IN IN G 0 7 | 2014 39

HEALTH & SAFETY

Training for safer mines Effective training that engages all levels of employees on a mine and quarry, and positively influences their attitude towards mine health and safety is important to reduce accidents and maintain a healthier workforce.

O SAYS Nico Pienaar, director of the Aggregate and Sand Producers Association of Southern Africa (Aspasa), encouraging quarry owners to find ways of training staff in a manner that makes them want to be part of broader initiatives to reduce health-and-safety-related incidents both at company and on an industry-wide level.

be applied in order to make a difference in the workplace. â&#x20AC;&#x153;This clearly indicates that the type of training offered to workers should therefore not be â&#x20AC;&#x2DC;standardâ&#x20AC;&#x2122; and needs to appeal to people on an individual basis in order to provide them with a deeper understanding of topics and how these topics relate to themselves and their colleagues in theÂ workplace. â&#x20AC;&#x153;Health and â&#x20AC;&#x153;Only about 10% of what is safety trainlearned on a normal training ing therefore course is retained.â&#x20AC;? needs to be developed to Nico Pienaar, director, Aspasa encourage individual participation, provide practical examples and appeal While standard-type training in the form to an individualâ&#x20AC;&#x2122;s sense of responsibiliof lectures and videos is commonplace in ty in order to ensure better retention of the industry, more effort should be taken learnedÂ material. to identify ways of actually engaging workâ&#x20AC;&#x153;They should be able to visualise what forces across different cultures and inspire they are being taught and, given practical them to implement what they are learning ways of applying it to their own workspace, into their own routines and workplaces. make it effective. They should also feel â&#x20AC;&#x153;It is important to note that only about empowered to apply whatever they have 10% of what is learned on a normal trainlearned to their own situations and should ing course is retained (and applied) by peobe given examples of how they can do so. ple once they return to their workplace. In For example, the importance of maintainthe context of health and safety, this is an ing a neat environment and then be given unacceptably low percentage, as every sinreal-life examples of how to organise their gle aspect of this type of training should

workspace and provide safe, convenient storage for their tools,â&#x20AC;? says Pienaar. He adds that scenarios need to be given that relate directly to the workers so that they can apply their own life experiences and identify behaviours that they have applied in the past. Once back at the workplace, they should be required to practice what they have learned in a positive and supportive way, which will help with the retention of learned material. Post-training follow-ups are therefore an essential part of any training program and should be checked by those responsible for the initial training, as well as encouraged by line managers and driven by senior management as a custodian of safety and health of workers. â&#x20AC;&#x153;Everyone should take part. Even senior managers should be actively participate and be part of the companyâ&#x20AC;&#x2122;s drive to improve health and safety.â&#x20AC;? In addition, the association seeks to actively support training initiatives in order to reduce health-and-safety-related incidents in mines to acceptable levels. â&#x20AC;&#x153;We encourage active training programmes at our sites and provide regular information and best practices whenever they become available so that we can work towards the industryâ&#x20AC;&#x2122;s goal of zero fatalities and zero harm by 2020,â&#x20AC;? say Pienaar in conclusion.

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HEALTH & SAFETY

The site psychologist Charissa Bloomberg is a self-styled ‘site psychologist’, with experience from mine sites to power stations, having just finished an 18-month contract at Medupi power station. By Gerhard Hope

OW THAT THE wages strike in the platinum sector by the Association of Mineworkers and Construction Union is finally over, the real work begins, says Bloomberg. “There is so much work to be done in this area. Besides the breach of trust and loss of faith, production is now behind and everyone has to make up for lost time and money. It is a recipe for disaster. “With all the problems that the mining industry faces, I think a site psychologist can play a hugely supportive role. In fact, I cannot believe this has not happened sooner. we are dealing with such a crisis. It is imperative, moving towards the future, that there is a role for a psychologist to play.” Bloomberg explains that the term ‘site psychologist’ evolved gradually over the seven years she has been travelling to different sites in South Africa and Namibia. “Someone along the way started calling me ‘the site shrink’. I think that is how the name started. It has also becomes a joke on-site when I arrive. This alone lifts the energy.” Bloomberg says that the role of ‘site psychologist’ has grown from initially just doing training to a broader range of duties. “I have written my own job description,” she says. A site psychologist differs from an industrial psychologist, who works more in the corporate environment, whereas a human resource specialist deals more with employment contracts and assists with demobilisations, industrial relations, performance reviews and in-house training.

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Personal level “I think that a site psychologist should know all the psychological issues that come from working on-site, whether it is mining or construction. On a personal level, it is very difficult for employees, as many live away from their families and go home once a month, or sometimes are away for much longer. This puts a strain on any family relationship. The divorce rate is high, so are the levels of alcohol consumption. Thus having a full in-depth knowledge of employees’ personal challenges is crucial.” Bloomberg explains that her first action as a site psychologist is to conduct a thorough needs analysis. “Sometimes mini team builds are needed between the site engineers and foremen due to a disconnect between these two groups; other times it is the burning issue of anger management. Everyone is so stressed that they lose their tempers. Pushing production is very stressful, especially if you are not making target.” The site psychologist also needs to be sensitive to motivation levels on a particular site. “Morale can be low, or there can be a manager, leader or contracts director who is micro-managing staff and who does not treat people with respect. The morale just drops, like it does before demobilisation.” Of course, a site psychologist must also be ready to be everyone’s personal psychologist. “Besides the training and team builds that I do, I also mentor people who want to improve their anger issues or their management styles. But I also open my door to staff ’s personal problems. People

are able to build trust with an outside person, knowing that I am not a permanent staff member; I work by myself and am contracted to a place for a certain period of time. I am not a threat and they know I cannot break confidentiality.”

Emotional intelligence The site psychologist must also be able to conduct emotional intelligence assessments in order to provide an outline of the strengths and weaknesses of workers and management, and how this impacts on the overall site. Then there is the issue of debriefing in the event of any accidents or deaths. “I was on hand to debrief a group after two died in a tragic bus accident. I have also been on hand many times when a family member has died or when someone is struggling at work.” Another critical aspect of the job is being able to deal with poor performance, which often means understanding the underlying causes or stressors. “A head of department once wanted to get rid of a female site engineer. He felt that she was useless. In a last-ditch attempt he asked me talk to her. Turns out her seven-month-old baby had swine flu. Once I got her the support she needed, she thrived, and has since become one of that company’s most productive engineers.” Despite all the careful planning and training, Bloomberg says that often an important crisis or flashpoint will take precedence, or someone needs to talk to her urgently. “So the day never turns out how you planned.” In addition to assisting ordinary employees, she also has to be able to

HEALTH & SAFETY

deal with people at top management level, such as directors. “Often huge contracts comprise joint ventures with three or more big mining or construction companies involved. Each has its own culture and way of managing and leading. This filters down to all levels, and can cause chaos. I feel that each construction company needs to come together beforehand and spend a day or so where they all discuss how they are going to move forward so that they can all be on the same page,” comments Bloomberg.

Work is never done Needless to say, a site psychologist’s work is never done when leaving a site either. “There are reports to write and research to conduct. I have co-published a paper on emotional intelligence in construction management, and have devised a stress-level measurement and motivational survey. I have also created a psychological incident mental status assessment for when there has been an accident or injury on-site.” Another issue is the potential danger. “There are huge dangers involved. I have been at Medupi when there were strikes and labourers were burning cars; also just travelling on the roads to get to site is a risk on its own.” Bloomberg is philosophical about the risks: “It does come with the job,” she says simply. “As well as the fact that there is a lot of responsibility to

“Of course, I have learnt to stand up for deliver results, proving oneself as a white myself. In fact, I have become fearless. I woman in a man’s world is also exciting, pop into offices, see individuals between but comes with pressures. training, and push hard to get changes. I “I had to prove myself initially and it was am on-site for a week, and in that time hard.” Bloomberg says she can get up to 16 I set my own targets for what needs to sullen, hostile men walking into her trainget done. I have had to learn to put up ing room at any given time, from HSE and boundaries, and yet be caring and helpsite engineers to foremen, questioning ful. My motto is why they were that I am there procrastinat“With all the problems to ‘uplift, inspire ing when they and motivate’,” had to oversee that the mining industry says Bloomberg. a multimillion faces, I think a site Perhaps the dollar conpsychologist can play a biggest problem, struction or surprisingly, is mining pro- hugely supportive role.” poor leadership ject. “I have and management on-site. This can create to win them over and get them to enjoy a powder keg of simmering stress, anger themselves,” says Bloomberg. and low morale. “I understand leaders “I have had to work hard. I have devised have a huge responsibility, but you get a fun way of training that has nothing to more from employees if you treat them do with Powerpoint presentations, but with respect. I can arrive on-site and do instead incorporates lots of roleplaying, a walkabout, and immediately feel the sharing, brainstorming and even devisenergy of the place. Usually this is closeing songs that incorporates the values ly related to leadership and how the site that they want to uphold in their teams.” is managed.” Although each mining and construcCultural diffuser tion site can be a study in contrasts, Bloomberg says that while she has learnt Bloomberg says that “the basic human a smidgeon of Xhosa, her main culturelement is the same. You have people al diffuser is humour. “I make the men struggling with the same problems, laugh in training. I swear with them and wherever you are.” catch them off guard. I take their side and help make their life easier in every way I can on-site. Medupi power station construction site

IN SID E M IN IN G 0 7 | 2014 43

MATERIALS HANDLING

Conveying what others cannot What sets BMG aside in bulk materials handling in the mining sector is the company’s ability to supply all components necessary for conveyor structures.

ONVEYOR STRUCTURES HANDLE a range of materials in harsh operating conditions. These products include belting, drives, bearings, couplings, motors and accessories, as well as gravity-flow materials-handling equipment. “The mining sector’s operating efficiencies are currently under enormous pressure, which is why BMG has implemented a programme to provide specialist services to the mines that ensure optimum mechanical reliability of plant and machinery,” says Derek Clifton, materials-handling sales manager, BMG (Bearing Man Group). The company’s extensive range of energy-efficient materials handling products, designed to facilitate reduced power

consumption, low maintenance and extended service life, is enhanced by a technical solutions support service. This service encompasses the initial design concept, specification of components and quality control, as well as the commissioning and maintenance of materials-handling equipment in use.

Range of materials-handling equipment BMG’s range of materials-handling equipment, which is constantly extended to meet growing market demand, now includes the 4B series gravity-flow materials-handling products, designed for efficient handling of solids in arduous mining conditions. The range of 4B series gravity-flow materials-handling equipment encompasses flap and rotary valves and hand, pneumatic and chain-wheel slide gates, lump breakers and feeding tees, as well as safety silo valves. Flap valves, also known as double-dump valves, are a type of airlock valve, designed for bulk materials-handling applications. These flap valves are used mainly to discharge powder or granular material from hoppers, bins and cyclones, operating under a pressure differential. Flap valves are often used to replace rotary valves, which can be jammed or damaged by fibrous or abrasive materials.

Flap valves Flap valves are manufactured from hard-wearing materials for extended service life in harsh operating conditions. Motor, pneumatic and gravity counter-weighted versions, which are available in standard and custom sizes, are enhanced by a range of sealing materials and stuffing-box seals to suit each application. BMG’s 4B series of fabricated heavy-duty slide gates are engineered as horizontal shut-off gates in gravity-flow applications for dry materials like powders, coals, granules and pellets. These gates are not suitable to seal in applications where a differential pressure exists. These slide gates are available in hand and chain-wheel, pneumatic and motor versions. A full range of standard sizes is available from BMG, and custom units are manufactured to exact specifications.

Lump breakers

ABOVE 4B FV flap valve LEFT Super Screw installation

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Also in the 4B series are lump breakers, which are integrated easily into an existing feeding system to break up material lumps that have compacted during transport or storage. A direct-coupled drive with counter rotating dual shafts breaks up compacted material between fingers and side combs

for improved product flow. These compact lump breakers can process materials that include chemicals, salt, lime and kiln dust, but are not suitable for crushing hard rock. Rotary valves and airlocks, which provide a constant volumetric feed rate, are recommended where there is limited space and where controlled feeding of powders and granular materials is required from silos, bins and hoppers. This multi-vane rotor provides accurate dosing and reduces leakage from cyclones and dust collectors into low- and medium-pressure pneumatic conveying lines. The same dropthrough metering valve can be utilised in pneumatic conveying lines by the addition of a venturi feeding tee.

Belt-fastener system BMG’s highly efficient belt-fastener system, the Super Screw, which was originally used as a temporary alternative to conventional hot and cold splicing, has proved to be totally reliable as a permanent splice for conveyor belt repairs, even in harsh mining environments. This high-strength splicing system is a flexible rubber splice using self-tapping screws that enable Super Screw to be installed, regardless of the configuration of the conveyor belt, ease of access and weather conditions. Field tests prove this is the quickest method to repair a conveyor belt in any emergency situation, reducing downtime significantly. The mechanical joining technique is easy to complete, without the need for a skilled operator and heavy, costly equipment. With training from BMG, an in-house maintenance team can install this product quickly and efficiently, using a battery or pneumatic screwdriver. There is no need for electrical power.

Leak-proof system This leak-proof system, with a high tensile strength, can be used for reliably joining a belt, repairing a longitudinal rip, or a puncture in a belt. The Super Screw splice is compatible with small pulley diameters, suitable for pipe conveyors and is conveyor scraper and V-plough friendly. This flexible splicing system can be used inserting new belting into old conveyor belt systems. Super Screw, which can withstand service tensions to 2 000 kN/m, is available in various grades of rubber, to suit exact requirements. The rubber material, containing tensile fabric used for the splices, is manufactured in rolls up to 25 m in length and in various strength ratings, from Class 315 to Class 2 000 conveyor belting. This system is also available in a readyto-install option, with maximum pre-cut lengths of 3 m and pre-installed assembly spacers. These materials are abrasion-, heat-, fire- or oil resistant and heat retardant up to 200°C. The non-magnetic system has metallic inserts made of stainless steel, with stainless steel screws. Steel screws are screwed into an embedded nut inside the material, forming a sandwich effect of the top and bottom covers that clamp onto the belt carcass. The surface of the splice is level with the two ends of the original belt, making the splice surface as even and as thick as the belt itself. It is fitted at the bias like regular splices to ensure optimal strength and flexibility around the pulleys. In selecting the correct Super Screw fastener for each application, factors to be considered include the belt tension and strength of the belt, as well as the final belt thickness required. I N S I D E M I N I N G 0 7 | 2 0 1 4 45

MATERIALS HANDLING

From static to

we use wireless power transfer, which is quite effective and helpful in environments where you have corrosive elements and also lots of other transport mechanisms that often overlap.” Known as Movitrans, this is what is billed as a contactless energy transfer system. In this system, electrical energy is transferred from a fixed conductor to one or more mobile consumers, without contact. Instead the electromagnetic connection is made via an air gap, which means it is not subject to wear-and-tear and is therefore virtually maintenance-free. “Another big advantage is that this type of power supply is emission-free and resistant to contamination from external sources,” notes Greyvenstein. Tested according to BGV B11, this is the perfect system for all applications, from industry to mining. In addition, the wireless communication is shielded in order to prevent loss and interference.

mobile conveying The latest trend in materials handling is the move from static to mobile conveying, says SEW Eurodrive. By Gerhard Hope

NDUSTRIAL GEARBOXES AND motors have long been the forte of SEW Eurodrive, but the company is also able to supply many other specialised products and solutions. Application engineer Theuns Greyvenstein recently spent nine months in Germany, receiving the latest training in order to allow the company to establish a new business segment in South Africa, called Maxolution, based on the most recent trends and developments in materials handling. “Traditionally we do sell a lot of industrial gearboxes and motors, for which we are well known in the market. Those typically tend to be more on the bulk materials handling side, for which realistically there are not that many alternatives. “However, once you get to the point where you have processed your material into a more valuable form and move higher up the value chain, you definitely find some interesting solutions.” In the mining and mineral processing industry, this

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would constitute the actual gold and platinum, for example. “In order to reduce the potential for pilfering, you want to limit human handling, especially with the higher-value commodities. The trend in the industrial environment is a move away from conveyor belts that just move products from A to B, and instead having an item or station that moves from A to B. “While such technology is already commonplace in the automotive industry, it is relatively new to the industrial sphere, and virtually unknown in the mining industry. “A big trend at the moment is the move away from static to mobile conveying,” says Greyvenstein.

Latest technology “The latest technology in this regard comprises wireless communication in addition to inductive power transfer systems. Instead of having cable trays or busbars to transfer power to these mobile solutions,

Inductive power supply The system operates as follows: an automatic guided vehicle (AGV) will use an inductive power supply in the form of transfer cables embedded into the floor. One of these is a leakage cable, which provides the communications, but in a very small range, so it is shielded. Alternatively you can use general wireless, which is antenna based. The AGV has a built-in safety feature that slows it down when into comes into the presence of any humans in or near its path. “This safety concept is based on a scanner that will detect any people in the vicinity, whereupon it will switch off and enter a ‘safe’ mode.” Greyvenstein adds that AGV can also make certain intuitive decisions about its route, based on the specific load it is carrying. “This system can actually go quite fast, reaching speeds of up to 2 m/s, depending on the load. Due to the safety technology, you do not have to worry too much about people being around. Especially in a mining context, I think this would be focused more on environments where you do not want people, due to the product value, or if it is environmentally hazardous.

MATERIALS HANDLING

RIGHT Movitrans for AGV OPPOSITE EMS System overhead conveying BOTTOM Movitrans hook up for EMS

“Although mining is seen as this robust industry employing a lot of people, it is moving away from that model simply due to the issues it is facing currently.” Greyvenstein adds that what makes such technology even more attractive to the mining industry is the health and safety aspect, in addition to the impact on productivity and efficiency.

Loads from 500 kg to 1 tonne “Some clients, for example, have expressed an interest in having such a system deployed between two stations that are quite some distance apart. The particular AGV in question can convey any load from 500 kg to 1 tonne. Depending on the speed, 1 tonne is a relatively large load in terms of final product.” Greyvenstein points out that SEW Eurodrive is able to offer a total solutions package for its mining customers. “Some of our competitors focus only on the inductive power transfer, and cannot provide the gearboxes and motors, whereas we provide all of that, including the positioning system, the wireless communication and d the power and control systems. Therefore re it is really a total solution package.” Additional functionality can be added to the system in the form of an integrated d hoist. “It is a very flexible system. Due to the positioning benefits, you can quickly ly and dynamically change your station layyout for different productions runs.”

to the company’s early success at the Two Rivers platinum mine, which standardised on SEW Eurodrive products, thereby creating a critical mass for the company and allowing it to grow ever since. Such local success has seen the company look to the rest of Africa for additional opportunities. “We do look at the whole of Africa as well. As this is new, we will

launch here and focus on Southern Africa; obviously it can be applied anywhere.” Greyvenstein says Africa will therefore become a testing ground to roll out this technology to mining areas such as Australia and Canada. “The international team is very much involved in providing back up to the new local business unit. Our official launch will be at Electra Mining Africa.”

Receptive to innovation While the mining industry prefers ‘trieddand-tested’ solutions as opposed to the he wholesale adoption of new technology, y, Greyvenstein says that the current issues es it is facing in terms of labour productivity ty and cost-cutting has made it more recepptive to innovation. It is for this reason that at SEW Eurodrive is targeting project houses es and consultancies as an entry point into to the mining industry, as this sector is offten more au fait with the latest trends and d developments, which slowly filter through h to the mining houses and specific projects. s. SEW Eurodrive became involved in the he mining industry in 2005, with the introoduction of its industrial gears. “We are re used to being the first to introduce new w technology and seeing it through to full ull acceptance,” says Greyvenstein. He points ts IN SID E M IN IN G 0 7 | 2014 47

MATERIALS HANDLING

resistance with the new liner plates, you are losing on the sliding abrasion or hardness of the plate.”

Impact tests The new liner plates are still undergoing impact tests in order to determine the limits and capabilities of the product. Maine points out that Rio-Carb will offer the same support to the new liner plates as it does for its other product ranges. “The aftersales support will be the same for all our products. There is very little variation between the new liner plates and our older products; the newer products are simply more impact resistant. Therefore they fit perfectly into our current product range. We provide full support on the liner plates and are readily available and open for repairs due to wear and tear, as long as there has been no negligence.” Maine highlights that the new liner plates allow RioCarb to expand its reach in the marchromium ket. “There was a gap in our product range, which has now been filled by the new impact-resistant liners. By filling this gap, we were also addressing a demand in industry for higher impact-resistant products. Our impact-resistant liners can now be used in areas where in the past we were restricted due to the impact factor. We are no longer restricted in those areas. We were specialised in the sliding abrasion market and now we are opening up into the impact abrasion market,” he concludes.

Thinner yet stronger Top liner-plate expert Rio-Carb has developed a new carbide impact-resistant liner plate.

HE NEW LINER plates can be used in areas and industries where previously chromium carbide plates were restricted due to their limited impact resistance. Rio-Carb director Martin Maine notes that there was a need to develop a chromium carbide overlay plate that is more impact resistant than previous Rio-Carb chromium carbide plates. “The new impact-resistant liner plates were developed by adding more

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manganese to the existing chromium carbide plate formulation, thereby changing the chemical composition of the product by making a manganese matrix rather than a carbon steel matrix, which is more impact resistant.” The new impact-resistant liner plates have a hardness of between 56 and 58 Rockwell C. Maine observes that normal chromium carbide plates have a measurement of 60 plus Rockwell C hardness. “Where you are gaining in impact

MATERIALS HANDLING

Splitting airs

IR PRODUCTS South Africa has launched its new, state-ofthe-art air separation unit at the companyâ&#x20AC;&#x2122;s Vanderbijlpark facility. It represents the largest single investment made by a local industrial gas company in the past decade. The R800 million G-Plant produces over 2 500 tonnes of oxygen, nitrogen and argon gas a day and is the sixth plant to be commissioned at the Vanderbijlpark site. G-Plant is the second largest gas-producing unit at Vanderbijlpark, which in turn is the largest dedicated gas manufacturing facility in the country. G-Plant forms part of an overall longterm capital investment pipeline of just under R2 billion. â&#x20AC;&#x153;This long-term capital investment strategy is the basis upon which we can build and develop our supply chain capacity and therefore ensure the future sustainability of the company, and

the industry as a whole,â&#x20AC;? explains Mike Hellyar, managing director of Air Products South Africa. The commissioning of G-Plant is the result of a mutually beneficial relationship between Air Products South Africa and Sasol, and is an expansion of the companiesâ&#x20AC;&#x2122; existing long-term supply contract. The new plant will supply Sasolâ&#x20AC;&#x2122;s expansion programme in Sasolburg, with pipeline gaseous oxygen and nitrogen in response to increased feedstock requirements. â&#x20AC;&#x153;While the G-Plant was commissioned in support of the Sasol One site expansion programme in Sasolburg, we will be leveraging off it to boost our overall supply capacity for the merchant market, as well as our production capability for pure argon, which will consolidate our market leadership in this area,â&#x20AC;? says Rob Richardson, on-site general manager at Air Products South Africa.

ABOUT THE COMPANY Air Products South Africa has a long-standing relationship with the mining industry through the supply of industrial gases and chemicals. A variety of our products are used to assist with the efficient extraction and refining of a wide range of metals. Gases such as oxygen, nitrogen, argon and hydrogen can be supplied either by dedicated, on-site supply plants or by truck delivery in liquid or gaseous form. It works closely with each customer to determine the most cost-effective supply mode based on volume, usage patterns, and purity or pressure requirements. In addition to gases, Air Products produces an array of performance chemicals that serve the mining industry.

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IN SID E M IN IN G 0 7 | 2014 49

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MATERIALS HANDLING

A crushing success Enduron brand

Weir Minerals Africa (WMA) offers a comprehensive range of equipment for a full crushing circuit, including screening technology. By Gerhard Hope

ROM THE WEIR Group’s acquisition of the Linatex group of companies to the in-house development of its own key products, WMA has transformed itself into a turnkey supplier for the comminution sector. It is also introducing its latest innovations to potentially lucrative and diverse markets such as Africa and the Middle East, from quarrying to iron ore and coal mining applications. Winchester Maphosa, product manager: comminution & screens, points out that South Africa is the design centre for screens for the entire Weir Minerals Division, and develops products for all its global markets. The design centre uses the latest in 3D modelling and finite element analysis software to create designs that

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provide performance and quality, with the aim of developing solutions with the lowest cost of ownership in the market. “With the start of our in-house development, we decided to consolidate our comminution offering and screens under a new brand,” explains Maphosa. “Screening equipment originally formed part of the Linatex stable, but this brand is well known for its superior rubber wear products and screen media. We wanted to house the screening equipment within a brand that actually identifies with comminution as a whole and hence our Enduron brand was established around April last year. I have no doubt that the Enduron brand will grow to represent everything that Weir Minerals is renowned for – technological excellence, innovation and quality.”

This development took place in conjunction with a new agreement with a crushing equipment supplier, which has enhanced WMA’s product offering to the point where it can supply a full comminution circuit. The Enduron brand runs the gamut from jaw to cone crushers, in addition to some feeders. WMA boasts a large screen manufacturing and assembly facility in Alrode, Johannesburg, with the flexibility to be able to cater for the smallest screen at a 0.3 m width, to the largest screen at a width of 4.3 m. “We are currently building nine double-deck, 3 m-wide screens for a project in Liberia,” reveals Maphosa. “It is a big project for us, and an achievement of which we are proud.” He adds that these are the largest screens to be manufactured at the Alrode facility since the acquisition of the Linatex group of companies. “We have a test bay for the full range of screens. We are also capable of refurbishing screens to an as-new state and we can test exciters up to a 120 tonne force,” explains Maphosa. WMA is also geared to support

MATERIALS HANDLING

and supply screens to its global counterparts, “because we possess competent skills in-house and are the most experienced screen manufacturer in the division.”

Cone crushers Since WMA’s debut in the crushing sector in 2013, it has started trialling its cone crushers in the global market, where it secured the installation of the first 200 hp unit. “The trial is progressing well, achieving performance to Weir’s high standards, and will serve as a local reference,” notes Maphosa. Another integral part of WMA’s pursuit of technical excellence has been the acquisition of a heavy bay foundry in Port Elizabeth. “This was a strategic acquisition, which, among others, gives us the capability to manufacture crusher wear parts and components in-house, in order to support our local and global installed base,” says Maphosa. “We are already gearing up to support our African installed base with locally produced wear parts. It is far more cost-effective in the long run, as well as reducing long lead times, which is critical for crushing customers.” The development of larger crushers is part of a concerted strategy to tap into the mining boom in Africa. “With our current 400 hp unit, we are positioned to compete in the small- to medium-size market. As significant growth opportunities exist in larger mining applications, we have development projects underway to support the customers in those markets.”

4.3 m-wide screens On the screens side, WMA has developed a range of 4.3 m-wide screens, which can also be supplied to larger mining applications globally. While these are not that prevalent in the local mining industry as of yet, they are a growing feature of major mining regions such as the Americas. “We actually have two orders that are currently being processed for delivery to Canada in 2015,” says Maphosa. In terms of new developments, WMA has been hard at work on the latest polyurethane (PU) screen technology to produce its Fusioncast PU materials for its Linatex screen media range. “This technology has been proven to provide longer wear life

than traditional PU technologies in many applications globally,” says Maphosa. He confirms that WMA has secured various trial sites to test such panels locally. “We are very excited to demonstrate the anticipated performance benefits,” he adds.

12 HPGR orders Another major development has been the focus on employing Weir’s in-house materials and engineering expertise to improve high-pressure grinding roll (HPGR) crushing performance. This has been made possible through a global technology license agreement with KHD Humboldt Wedag, which has enabled WMA “to further leverage existing in-house world-class manufacturing facilities for the manufacture of various components of the machines.” Maphosa comments: “Globally we have had some great success since commencing our relationship with Humboldt Wedag. Since 2010, WMA has managed to secure 12 HPGR orders for various projects. It has also successfully carried out a number of roll exchanges for existing installations around the globe.” In terms of customer support, Maphosa says: “We have fully trained and competent service and maintenance teams that support our prod-

The team is also able to offer full aftermarket services such as audits and maintenance supervision. Not content with expanding its footprint in Africa, WMA is also looking to the quarrying sector in the Middle East. “With our comminution products, we can leverage our presence in the area to provide solutions to the rapidly expanding quarrying sector in the Middle East.” In terms of growth opportunities on the continent, Maphosa says: “We are looking more at projects in the iron ore sector, while locally there is also some activity in the coal sector. “In general, the project environment is low. However, there are still many opportunities as planned expansions come to fruition. There a lot of challenges facing the mining industry at the moment. However, these are the sorts of challenges that WMA thrives upon, and which will see it continue its innovation drive to further improve its comminution range for its clients.”

“We are already gearing up to support our African installed base with locally produced wear parts.” Winchester Maphosa, product manager: comminution & screens ucts across our range of comminution equipment, with capabilities from manufacture to installation and c o m m i s s i o n i n g.”

OPPOSITE TOP The new Enduron cone crusher being installed on-site in South Africa RIGHT TOP An elevated view of a KHD HPGR machine being assembled RIGHT BOTTOM A 3.7 m-wide Enduron horizontal screen on the test bed at Weir Minerals Africa's Alrode facility

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MATERIALS HANDLING

Cyclone efficiency boost A major market differentiator for Multotec is the unique design of its classification cyclones.

The vortex finder is used to control the cut point inside a classification cyclone, which means that the vortex finder can be selected to allow for more or less material reporting to the overflow, as well as for finer or coarser particles. This ability to make an appropriate selection makes it is easier to control the performance of the cyclone, and to fine tune the product requirements. Bekker cautions, however, that if the vortex finder is changed, it not only changes the cut point, but also the operating pressure and this must be taken into account.

Varying spigot diameters Without changing the entire cyclone design, Multotec is able to accommodate varying spigot diameters and achieve optimum underflow densities. The Multotec spigot has a parallel throat design, which enables it to maintain the A selection of cyclone products from the Multotec cyclone range

HESE INCORPORATE engineering that makes it possible to alter several components during the design stage, or even after installation, to ensure that the cyclone meets customers’ exact performance requirements. “Our metallurgical engineers have the necessary levels of expertise and skill to ensure the most appropriate cyclone solution,” Ernst Bekker, product specialist, Multotec, says. “When designing and engineering a cyclone or cyclone cluster, we take into account not only the cyclone itself, but also our understanding of upfront and downstream processes. “For example, if a very fine cut point is required, standard simulations will dictate the use of small-diameter cyclones. However, if the feed stream contains fairly large particle sizes, this could cause blockages at the inlet of a small-diameter cyclone. Therefore the selected cyclone configuration has to take into consideration operational constraints, while still satisfying the process requirements.” An example which clearly underpins this capability is a classification cyclone cluster Multotec recently installed in a milling circuit. The grind of the mill circuit was much coarser than what was originally

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anticipated and this resulted in extreme circulating loads that limited the throughput capacity of this process.

Alternative solution “The customer asked us to present an alternative solution,” Bekker relates. “Essentially, a change in cut point was required on the cyclones. The first option was to install larger-diameter cyclones and the second, considered far more cost-effective, was to alter the existing cyclone configuration. In the first instance, installing the larger-diameter cyclones would have necessitated a total re-engineering of the cyclone cluster with associated infrastructure changes, downtime and cost implications. “Multotec proposed the second option as as it required limited modifications to the cluster. The seriousness of this situation should not be understated, as the significantly reduced throughput from this milling circuit could have had severe long-term financial implications for the operation. The conventional cyclone was converted to a flat-bottomed cyclone by modifying certain components and the cone angle. This design modification achieved the required throughput and the bottleneck in the milling process was relieved.”

correct spigot opening over a longer period of time. “This design is important; the reason being that in most operations where conventional cyclones are used as the spigot starts to wear, the amount of bypass water to the underflow starts to increase, as the spigot diameter increases, which then leads to an increase in the misplacement of fine material to the underflow, and reduced hydrocyclone efficiencies,” he explains. The cone angle is selected based on customers’ requirements. By changing the cone angle for the same cyclone diameter as opposed to altering the cyclone diameter, the cut point of the cyclone can also be altered to make the separation cut point coarser or finer. This also allows for a high degree of flexibility and the ability to customise for specific applications. An advantage of the rubber-lined hydrocyclone is the inclusion of weep holes, which have been a feature of this range from the mid-1990s. This allows for early detection of internal damage, which reduces the frequency of unplanned stoppages. Early detection allows for higher overall cyclone efficiencies as the damaged liner can be easily and quickly replaced due to the loose rubber-lining technology used inside these units.

MATERIALS HANDLING

Slick lubrication solutions The SKF SYSTEM 24 TLSD series lubricator is an electromechanical, single- point, automatic lubricator that provides direct or remote lubrication.

HE LUBRICATOR IS A standalone device, consisting of a lubricant reservoir and a battery powered unit that can be programmed to dispense lubricant in various monthly settings. The drive unit uses a simple rotary switch, protected by a clear plastic cap, which enables the programming of the TLSD to dispense lubricant in intervals of choice. Each machine is connected

via either a direct mount or a feed line, each terminating with a standard G1/4 thread. The lubricators are simple to fit, easyto-use and very reliable. The programmable drive unit offers more options and greater flexibility. The transparent reservoir makes it quick to check the status at a glance and the light LED display clearly shows the operating

status of the device. The reservoir, which is is available in two sizes (125 ml and 250 ml), is filled with SKF-specified high performance oils or greases. Maximum operating pressure is 5 bar. The robust TLSD lubricator is especially suitable for use in applications with high levels of vibration or fluctuating operating temperatures; a special version is also available for operation in cold temperatures. The product offers an effective solution for the lubrication of bearings, shafts and spindles, helping to extend machine operating life and reduce maintenance costs across a wide range of applications including pumps, fans and blowers to conveyors, escalators and cranes.

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SKF South Africa - Celebrating 100 Years of Innovative Solutions

Mining Industry Solutions Harsh operating and market conditions make the mining industry a tough customer. SKF’s advanced range of products and services in the SKF Life Cycle Management approach - SKF’s proven approach for reducing Total Cost of Ownership for machinery at every stage, from speciﬁcation and design to operation and maintenance, can help! SKF solutions assist with increased productivity and proﬁtability, improved worker safety, reduced environmental impact, cutting energy consumption and reducing unplanned downtime.

SKF South Africa is celebrating 100 years of innovative solutions during 2014. Drawing on ﬁve areas of competence and application-speciﬁc expertise (bearings and units, seals, lubrication systems, mechatronics and a wide range of services), SKF brings innovative solutions to OEMs and production facilities in every major industry worldwide.

The Power of Knowledge Engineering SKF South Africa (Pty) Limited Tel: +27 11 821 3500, Fax: +27 11 821 3501 Email: sales.za@skf.com, Web: www.skf.co.za

MATERIALS HANDLING

Forklifts go 4WD

TX4 all-terrain forklifts – which can be fitted with specially designed attachments for various materials-handling tasks – ensure efficient operation, low maintenance, optimum safety and extended service life in arduous conditions. TX4 high-lift forklifts, with an all welded steel chassis and frames for optimum strength, offer resistance to dynamic/ shock loads. Optional heavy-duty mast and carriage configurations are available.

Telescopic mast

LT SA’S extensive range of Taylor materials-handling equipment now includes the TX4 series articulated 4WD forklift trucks, designed for moving materials in the harshest environments, including muddy and rough terrain.

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Unlike other comparable articulated forklifts, this series is not a front-loader chassis with a fork attachment, but a robust articulated material handler, completely designed and engineered in the US by Taylor Machine Works, says Charity Gumede, marketing director of BLT SA.

The telescopic Ultra-Vu mast features a nested channel construction for clear visibility of the fork and other attachments. Double-acting lift cylinders are positioned to the rear of the mast rails, while high-strength multi-leaf lift chains are nested inside the mast rails. These machines have a 16° forward and backward mast-tilting capacity. Benefits include a heavy-duty bolted planetary drive axle; large, all-terrain tyres for good traction in harsh environments; and fully adjustable, pin-mounted forks forged from heat treated steel allow for flexibility of operation.

MATERIALS HANDLING

Lock out potential hazards

EW TO MAGNETâ&#x20AC;&#x2122;S extensive portfolio of electrical equipment, industrial instrumentation and automation systems are robust lockout/tagout devices designed to restrict access to hazardous equipment, thus minimising the risk of accidents or injury of employees. These new, locally manufactured lockout/tagout devices, which ensure optimum protection of high-risk machinery, are specially labelled to individual requirements to warn against the dangers of equipment in industrial environments, says Brian Howarth, managing director of Magnet. A plant that has implemented the correct lockout/tagout procedures minimises the risk of injury or accidents caused by negligence during maintenance and repairs of electrical equipment. These devices are designed to the specific lockout requirements of leading circuit

breaker manufacturers, including Schneider, ABB, Siemens, Eaton and Mitsubishi. Whether the panel door is open or closed, this lockout/tagout system ensures absolute safety. By disengaging lockout HASPS, which are safety precaution devices used to fasten a door or gate, the employee acknowledges awareness of the potential danger of machinery in the restricted area. This system is more effective than simply having a danger sign alongside equipment. Keys are stored in distinctly marked safety enclosures, which are mounted on a wall close to the machinery. These enclosures act as a safety check points to prevent the inadvertent start-up of a machine that is undergoing repair or maintenance. Included in this range are plug, cable, valve, cylinder and pneumatic lockouts, as well as circuit breaker and electrical panel devices. IN SID E M IN IN G 0 7 | 2014 55

INDUSTRY NEWS

BME pays tribute to its extraordinary people BME, one of the largest supplier of explosives to surface mines in South Africa, and a major supplier of explosives across Africa, recently celebrated its 30th anniversary.

ANAGING DIRECTOR Francois Hay, highlighted the company’s humble beginnings and meteoric growth. “We retain that original humility, with the confidence and innovation of a company that can deliver and that will take our customers beyond mining explosives. In all of this, the high standards we maintain in safety, health, environment and quality are not negotiable.” Hay cites the company’s greatest achievement as still supplying Kumba’s Sishen iron ore mine with raw materials 30 years later. “I believe this longevity is because BME’s employees are committed to exceptional standards of service, which continually exceed the expectations of our customers.

“BME is poised for the challenges the future might hold in mining locally, in Africa and beyond.” Francois Hay, MD, BME

who get up, take hands and support each other in tough times to ensure the job is done no matter what. People who are innovative, often with limited resources. People who seem to really enjoy what they do. What a privilege to be part of this awesome, diverse and talented BME family.

Spirit of entrepreneurship “Many of the BME team have 10, 15 and even 20 or more years of service. The culture and values that BME and Omnia embrace are not endorsed by fancy framed motivational credos in the passages, but are embedded in the hearts of a family of people; the spirit of entrepreneurship and challenge to achieve success. “BME is poised for the challenges the future might hold in mining locally, in Africa and beyond. But past performance is no indication of future success. It will not be easy. Competition is fierce everywhere we go and new business is scarce. We will have to be extraordinary. We have to ensure our people are the best, well trained and always carry the customer’s best interests at heart.”

Extraordinary team “When I joined BME 11 years ago, I was mostly struck not by the achievements, the standards nor BME’s growth, but by its extraordinary team of people. “People who work with passion, commitment and tenacity; people who work hard,

INDEX TO ADVERTISERS Adapt IT Advanced Vehicle Engineering Akhani Group Babcock Equipment

IBC

Hencon Vacuum Technologies

Schneider Electric

IFC

I-Cat Environmental Solutions

SEW-Eurodrive

Komatsu South Africa

SKF SA

Southern Mapping

OFC 2

Bell Equipment

Leadership for the Mining Shop Steward

Booyco Electronics

M&J Engineering

Tenova Mining & Minerals

OBC

ThyssenKrupp

MSA

Vital Engineering

Multotec Group

Voith Turbo

FLSmidth

Rio-Carb

WorleyParsons

GS Hygiene

SBS Water Systems

Vermeer Equipment Suppliers

Electra Mining Africa

Fire Trucks 4 Africa

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