www.miningne.ws
af r ic an u pdates on th e
Chamber of Mines Fast-tracking modernisation
g ro un d a n d un d e rg ro un d
Wescoal
Transforming the sector
Saving energy Going beyond motor efficiency
k c o c bab nches the
lau perfect pair
Nick Holland, CEO of Gold Fields, talks about a mechanised approach to mining, his recipe for success, and the company’s future plans
ISSN 1999-8872 • R50.00 (incl. VAT) • Vol. 10 • No. 06 • June 2017
contents
a f r i c a n u p dat e s o n t h e g ro u n d a n d
u nde rground
Booyco PDS
08 Editor’s Comment
Fossil Fuel Foundation
3 Everyone’s talking about mechanisation
22 Effectively capturing coal emissions
Cover Story
Earthmoving Equipment
4 Perfect pair now in South Africa
25 Bell’s E-series ready for delivery
14
june
26 ADT for all conditions
Africa Round-up
Transport & Logistics
6 News from around the continent
28 Making transport safer
Gold Fields
2017
Transmissions, gears & motors
8 Mechanisation for maximum results
30 More than energy-efficient motors
12 Damang’s reinvestment plan
ON THE COVER p4
Health & Safety Wescoal
The device allows for interventions – through both visual and aural signalling – where a potentially dangerous situation exists between a pedestrian and a machine
34 Spray-on liners for gas management www.miningne.ws
14 Contributing positively to transformation
Company News
16 Taking Elandspruit underground
37 Renewing collaboration, improving safety
afr ic an updates on the
Chamber of mines Fast-tracking modernisation
Chamber of Mines
Market News
19 Fast-tracking modernisation
38 The latest news from the mining industry
ground and underground
WesCoal
Transforming the sector
saving energy Going beyond motor efficiency
cochceskthe balabun t pair perfec
Nick Holland, CEO of Gold Fields, talks about a mechanised approach to mining, his recipe for success, and the mine’s future plans
22
30
ISSN 1999-8872 • R50.00 (incl. VAT) • Vol. 10 • No. 06 • June 2017
Volvo Construction Equipment’s muchanticipated 60 t A60H articulated dump truck and 90 t EC950E crawler excavator have been launched in South Africa
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1
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editor's comment
Publisher Elizabeth Shorten Editor Mientjie Kleinhans Journalist Phila Mzamo Head of design Beren Bauermeister Design consultant Frédérick Danton Chief sub-editor Tristan Snijders Sub-editor Morgan Carter Contributors Tristan du Pisanie, Rosemary Falcon, Norman Maleka Client services & production manager Antois-Leigh Botma Production coordinator Jacqueline Modise Marketing manager Mpinane Senkhane Head: e-commerce Roxanne Segers Financial manager Andrew Lobban Administration Tonya Hebenton Distribution manager Nomsa Masina Distribution coordinator Asha Pursotham Printers United Litho Johannesburg Tel: +27 (0)11 402 0571 ___________________________________ Advertising sales Annemarie Prins Tel: +27 (0)11 233 2600 annemarie@3smedia.co.za ___________________________________
No. 9 3rd Avenue, Rivonia 2191 PO Box 92026, Norwood 2117 Tel: +27 (0)11 233 2600 Fax: +27 (0)11 234 7274/5 www.3smedia.co.za ___________________________________ Annual subscription: South Africa: R550.00 (incl vat & postage) African countries: US$80 Foreign: US$100 Email: subs@3smedia.co.za ISSN 1999-8872 Inside Mining Copyright 2017. All rights reserved. ___________________________________ All material in Inside Mining is copyright protected and may not be reproduced either in whole or in part without the prior written permission of the publisher. The views of contributors do not necessarily reflect those of the publishers.
W
hether we like it or not, mechanisation and the move towards automation are among the most popular topics of conversation. Some of the bigger mines, such as Gold Fields, wouldn’t even consider
another method of mining; but, is the industry really ready? Obviously, mechanisation is not the ideal answer for every mine. Junior
miners have to look at the best value for their money and return on
Everyone’s talking about mechanisation
investment, and if mechanisation doesn’t fit into that budget, other methods of mining will be considered. Another area where mechanisation is not the ideal solution is where reserves are at such an angle that the use of mechanised
machinery wouldn’t be possible. So, there are certainly instances where mechanisation isn’t a practical progression or solution. Talking to Nick Holland, CEO, Gold Fields, about his company’s recipe for success, and how the company has undergone quite the turnaround, he explains that Gold Fields will only consider mechanised mining going forward. At the Investing in Africa Mining Indaba earlier this year, mechanisation was also a hot topic. Neal Froneman, vice-president of the Chamber of Mines and CEO of Sibanye, also discussed how some people in the mining industry will lead the way while others will have to be dragged, kicking and screaming, into the era of new technology. Read more on page 19. In an interview with Waheed Sulaiman, CEO, Wecoal, he speaks about the company’s 59% transformation deal that was finalised in December 2016 and its key points. He also speaks about Wecoal’s plans for growth, but doesn’t reveal any trade secrets! Sulaiman also believes that for government and the mining industry to work together and uplift the economy, there has to be a level of trust between the parties as a starting point, and then high levels of communication. More about this in the interview on page 14. Another highlight in this edition is Professor Rosemary Falcon’s article on coal being under threat on many fronts from the global climate change community. She discusses why it is vital to understand the problems concerned with the use of coal and to use methods that ensure its wise and clean use. Read more on page 22. There are other interesting articles in this issue in our
To our avid readers, be sure to sign up and get the latest updates and inside scoops from the mining industry. Check out what we are talking about on our website and Facebook page, or follow us on Twitter and have your say.
earthmoving feature, transport and logistics feature, and other news. And also, always remember to look out for industry insights and happenings on MiningNe.ws!
Mientjie Kleinhans @mining_news www.facebook.com/pages/ Mining-News
In sid e M in in g 0 6 | 2017
3
COVER STORY | Babcock
EC950E
A60H
The Perfect pair
now in sa T
Volvo Construction Equipment’s muchanticipated 60 t A60H articulated dump truck and 90 t EC950E crawler excavator were officially launched at Babcock’s state-of-the-art Middelburg facility in May 2017.
his is the first time that the two machines will be available for purchase in South Africa following the
unveiling at the Bauma exhibition in Germany last year. The A60H and EC950E are exclusively available in Southern Africa through Babcock, the sole regional distributor of Volvo Construction Equipment (CE).
Supporting the heavyweights David Vaughan, managing director of Babcock's equipment business, says that Babcock is fully prepared for the roll-out of the A60H and EC950E. Volvo teams from Sweden and Korea have completed intensive sales and technical training with Babcock staff in South Africa, while Babcock has ensured that there is sufficient availability of Volvo spare parts and other related elements such as the larger specialised tyres that the A60H utilises. He adds that Babcock has partnered with local vendors to develop solutions for the aftermarket for both machines, such as fire suppression, automatic greasing and collision avoidance systems. In preparation for the roll-out, Babcock has been appointed as an accredited Allison transmission service dealer to be able to undertake repairs and servicing of the fully automatic Allison transmissions that form part of the backbone of the A60H dump truck. The response to the launch exceeded all expectations with existing and prospective customers
attending from all over Southern Africa. To date Babcock has secured firm orders for six A60Hs and are in the process of firming up orders for the EC950E. “The A60H and EC950E are eminently suitable for local mining operations as their robust drivelines are
he A60H and EC950E are T eminently suitable for local mining operations as their robust drivelines are designed specifically for challenging applications.” David Vaughan, MD: Equipment, Babcock International Group
designed specifically for challenging
Superior digging force
with wear-resistant steel plates, perfect
applications such as those found in the
With over 424 kN of breakout
for quarrying and mining applications.
Southern African mining environment,”
force and 408 kN of tearout force,
says Vaughan. “The A60H articulated
the EC950E offers the perfect
Customer support agreements
dump truck, in particular, is
combination of power and stability
Both machines can be purchased
perfectly suited for open-pit coal
to handle high-capacity duties in the
from Babcock with Customer Support
mining where short yet extremely steep
toughest applications.
Agreements offering preventive
ramps have to be climbed to access
The 90 t EC950E is Volvo’s largest ever
maintenance, total repairs and a
box cuts made through overburden in
crawler excavator that combines
number of uptime services, while
order to expose high-grade coal.”
power and stability to handle a higher
the latest in Volvo technology is
capacity in the toughest applications,
used to monitor machine operation
and has been designed to load the
and status, ultimately resulting in
The A60H can move more tonnes per
massive A60H. The EC950E heavy-duty
increased profitability to customers
hour and gives 100% in all conditions.
excavator delivers best-in-class fuel
and the retention of asset value.
The largest articulated hauler on the
efficiency and features a powerful
market, it has a bigger payload for
16 litre engine, a new electro-
support services and facilities for Volvo
heavy-duty applications, delivering up
hydraulic control system, Volvo’s
CE and is one of the most established
to 40% more productivity than Volvo’s
unique ECO mode and an
and experienced equipment suppliers
previous largest hauler. The Volvo
ergonomic operator environment.
in Southern Africa, with an extensive
Meet production targets faster
A60H embodies the full articulated
The EC950E features a wide
Babcock offers full aftermarket
footprint in the region and a proven
hauler concept and provides total
track gauge, long track length, a
track record for delivering to the
versatility so that the entire jobsite can
retractable undercarriage and an
highest standards. Both Volvo CE
be accessed and steeper gradients
optimised counterweight, resulting
and Babcock are confident that the
climbed. It works in all seasons, terrains
in a well-balanced, solid machine.
excellent reputation currently enjoyed
and applications using tailored
All machine interfaces – including
by the Volvo excavator and ADT
machine configurations and tyres
joysticks, keypad and LCD monitor
product lines in Southern Africa will be
that have been optimised for the 60 t
– are ergonomically positioned and
further enhanced with the introduction
machine. Goodyear, Bridgestone and
designed for optimum control and
of the A60H and EC950E.
Michelin will manufacture the
efficiency. Operators can work with
specialised tyres required for the A60H.
comfort and confidence in the most
The A60H has several features that
challenging environments in the
will be familiar to current A40 series
comfortable, spacious and low-noise
operators, eliminating the need for
cab of the EC950E.
major retraining. Operators will only
Volvo’s durable, high-quality
require a short orientation course and
buckets are perfectly matched to
technicians who regularly service
the EC950E for digging in all working
other Volvo dump trucks will have
conditions. The general purpose, heavy-
knowledge of many of its elements.
duty or extreme-duty buckets are built
www.babcock.co.za
In sid e M in in g 0 6 5 | 2017
5
Mining news
from around the continent
south africa
amount could greatly reduce the net
to the socio-economic well-being
emissions at many of our mine sites in
of the country and our communities,
Diamond miner De Beers will lead
the near future, and possibly lead to
and to supporting South Africa’s
a groundbreaking research project that
carbon-neutral mining at some sites
transformation agenda,”
aims to deliver carbon-neutral mining at
within the next five to ten years,”
Mpofu added.
some of the company’s operations in as
said Mervine.
Carbon-neutral research project
few as five years.
The Bophelong Stimulation Centre is
De Beers started the project in 2016.
the first specialised facility in the area
Assessment studies are currently under
and will provide care, protection and
will see the company’s scientists
way for Venetia Mine in South Africa
stimulation for children with mental
working in close collaboration with
and Gahcho Kué Mine in Canada.
and physical disabilities who are also
The project, led by Dr Evelyn Mervine,
a team of internationally renowned scientists to investigate the potential
South32 and DMR
affected by poverty. Mpofu said that mining was an
to store large volumes of carbon
A stimulation centre offering
important contributor to South Africa’s
at its diamond mines through the
development opportunities for mentally
economic and social aspirations and,
mineralisation of kimberlite tailings.
and physically challenged children has
importantly, that it provided a vehicle for driving shared value. “By shared value, I mean identifying opportunities that create economic value while also advancing the environmental and social outcomes of the communities and regions in which we operate,” she explained.
Tanzania
Illegal mining reduces water supply Illegal alluvial gold mining and environmental degradation in steep slopes and on river banks in the East Usambara Mountains are destroying water sources for over 300 000 urban residents in Tanga. The Tanga Urban Water Supply Mervine said, “This project offers
been handed over to the Dipaleseng
and Sanitation Authority (Uwasa)
huge potential to offset the carbon
NGO community. South32 provided
says it loses a total of Sh15.2 million
emissions of De Beers’ diamond mining
funding for the construction and
(US$ 6 800) every day in revenue
operations completely.
outfitting of the Bophelong Stimulation
collection and increased costs of
Centre in Balfour, Mpumalanga.
water treatment as a result of a serious
“Mineral carbonation technologies are not new, but what is new is the
Speaking at the handover event,
application of these technologies
South32’s vice-president: Corporate
Dam, the major water source
to kimberlite ore, which is found in
Affairs Africa Region, Dr Patience
feeding Tanga.
abundance in the tailings at diamond
Mpofu, said, “South32 is proud
sites, and which offers ideal properties
to launch the centre through a
director, Tanga Uwasa, said that mud
for the storage of very large volumes
collaborative partnership with the
flowing from Muzi River, which feeds
of carbon.”
Department of Mineral Resources and
into Zigi River that, in turn, flows into
the local municipality.”
Mabayani Dam, has increased the
“We are committed to contributing
turbidity of the water from the normal
De Beers noted that it would pioneer the project, which aims to accelerate what is already a naturally occurring and safe process of extracting carbon from the atmosphere and storing it at a speed that could offset man-made carbon emissions. “The research is in its early stages and it may take some time before it is economically or practically achievable to tap into this full storage potential. However, even just tapping into a small
6
Ins i de Mi n i n g 0 6 | 2 0 1 7
increase in turbidity in the Mabayani
Joshua Mgeyekwa, managing
Zimbabwe
100 NTU (mud level units) to 600 NTU.
Collusion costs Zimbabwe’s diamond industry
mining companies into Zimbabwe Consolidated Diamond Company. Seven firms operating in Chiadzwa –
“We have been forced to cut water
Zimbabwe may have lost substantial
namely Mbada Diamonds, Anjin,
production because the kind of
potential revenue from diamonds
Marange Resources, GyeNyame,
chemicals we use for water treatment
after Belgian firm First Element –
Kusena, Jinan and Diamond Mining
cannot clean a large amount of water
contracted to clean and sort the gems
Company – were to merge into one
at one time,” Mgeyekwa said.
– allegedly picked buyers for local
entity, ZCDC, where government would
auctions in a dodgy scheme crafted to
hold a 50% share.
Zambia
facilitate collusion. A Parliamentary Portfolio Committee
The investors would hold shares in ZCDC as per the investment they had
Case against First Quantum dropped
on Mines and Energy’s report on
Zambian President Edgar Lungu told the
also says Zimbabwe might have lost
Lack of company appraisal
state investment company to drop its
huge potential revenue due to lack of
The aforementioned parliamentary
fraud case against the country’s biggest
value addition and understanding of the
committees noted that First Element
copper producer and some of its
diamond industry.
was hand-picked by the secretary for
directors, his spokesman said. Arbitration
put in thus far.
consolidation of diamond mining firms
Part of the reason was that the
over the matter will
marketers of diamonds,
continue in London.
especially from the
mines without proper due diligence to ascertain its capability and credibility. Over time, operational deficiencies
Marange diamond fields,
were noted by the Minerals Marketing
Minerals, based
did not understand the
Corporation of Zimbabwe (MMCZ) and
in Vancouver,
diamonds’ footprint and
highlighted “to the executive”, but
had written to
only after feedback from
MMCZ management was threatened for
Zambia’s attorney-
the market did it become
interfering with First Element.
general expressing
apparent they sold some
First Quantum
fears that directors named in the case
unique gems far below the real value.
This comes amid a slew of alleged impropriety – financial and administrative – levelled against Mines
could be arrested if they enter Zambia, where it produced more than 70% of
Consolidated firms
and Mining Development secretary
its copper last year, and asked him
Negligible revenue and lack of
Professor Godfrey Gudyanga. The
to intervene.
transparency in the sector caused
committee has recommended that
government to combine the diamond
Gudyanga be dismissed from his post.
ZCCM Investments Holdings, which has a 20% stake in First Quantum’s flagship Kansanshi Mine, also started arbitration proceedings against the company in London last year. “The instruction is firstly to reach an amicable settlement,” Amos Chanda, Lungu’s spokesman, said. “The settlement presupposes that the arbitration case in London will continue but these other actions that have been started here in Lusaka have to stop.”
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gold fields
Mechanisation for maximum results Gold Fields’ focus is to mechanise its operations, which is precisely what it is doing at South Deep Mine in Westonaria, Gauteng. Nick Holland, CEO of Gold Fields, talks about the role of mechanised mining, his recipe for success, and the mine’s future plans. By Mientjie Kleinhans Underground at South Deep Mine
T
he year 2016 was one of Gold
In terms of our overall cash flow for the
rate improving by 30% against the previ-
Fields’ best years in recent histo-
group, we more than doubled that from
ous year,” says Holland.
ry in that it managed to achieve
US$123 million to $294 million in 2016,”
the upper end of its restated
says Holland.
8
Recipe for success
The one negative in 2016 was one
Holland says that the mine’s recipe for
guidance during the year and got to the
fatality, where an employee was un-
success was developed by reviewing
upper end of the restated guidance by
fortunately lost at South Deep in Sep-
the original 2012 strategy and targets,
the end of the year. We thought our pro-
tember after a seismic event. “Apart
and understanding the positive and
duction was initially going to decline in
from that, we believe everything else
negative trends since then. “We worked
2016 but, instead, it came in at the same
went extremely well. Despite the fatal-
out that the industry was far too focused
level as 2015. It was a very good year
ity, our overall safety performance has
on ounces of production instead of cash
and we also managed to drop our costs.
improved with the total injury frequency
flow. Therefore, we decided to move
guidance. “We upped our production
Ins i de Mi n i n g 0 6 | 2 0 1 7
gold fields Exploration taking place at the Gruyere Project, Australia
away from just trying to chase growth
coming through. At the same time, this
working on the rock face or the drill rig
in production to rather seeking ways to
allows us additional capital to reinvest in
operator, to the truck driver, the load
grow the cash flow. And we don’t nec-
the business to keep that cash flow go-
operator, and everyone else. “They
essarily grow the cash flow by growing
ing in future,” says Holland. He adds that
need to understand the key principles in
the production. It can often have the
there is no point in investing for future
the business. That is how we got a recipe
opposite effect if the production process
growth for one year or two years, then
for success for the future,” says Holland.
is too costly.
letting it fall away. It has to be done year
Even though Gold Fields is the seventh
after year, and the mines now plan to
largest gold producer in the world, it only
ing, stopped chasing projects around
invest sufficient funds in the future devel-
has eight operating mines.
the world in different countries, spread-
opment of the gold ore bodies to ensure
ing ourselves too thin, and spending too
that they can maintain and, where pos-
“We started cutting out marginal min-
much money. We sold a lot of projects, we unfortunately cut our global workforce by 12%, and we turned the operations around over a four-year period,” explains Holland. In 2012, the company lost $218 million. Four
sible, grow their future cash flow. Holland explains that the company spends a
“A simple philosophy: don’t produce ounces that don’t make money.”
years later, in 2016, the company – with lower gold prices – was $294 million cash positive with all the interventions that it has done and by focusing on cash flow instead of production. “We adopted a simple philosophy: don’t produce ounces that don’t make money and ensure that we drive our profit margin. We said to our operations that they need to make a 15% margin after all their costs per ounce, otherwise they shouldn’t be mining those ounces. “It takes a while to embed – it has taken us probably two to three years – but those are the results that are now
lot of time trying to spread this culture throughout the
Challenges in gold mining Holland says that the problem it is faced with in terms of gold mining is that ore bodies are becoming deeper, it is becoming more complex to process metallurgically and new additional processes are needed to liberate the
workforce, from
gold. Conventional cyanidation doesn’t
the person
always liberate the gold from the ore
The Gruyere Project in Australia in the construction phase
gold fields
body and one has to have some down-
“How do we move away from very
it can reduce costs and it will make ore
stream process to capture the gold,
labour-intensive, conventional mining
bodies viable that otherwise wouldn’t
which means more capital, more op-
in South Africa? How do we get to
be viable. That is the way I think the
erating costs, but it doesn’t guarantee
mechanisation that requires more skilled
industry is going to transform over the
the full recoveries.
people and, ultimately, automation,
next five to ten years.”
Gold is becoming scarce in the world and the grades are declining as we
underground and certainly no people
Innovative technology
go deeper and the cost of extracting
at the rock face? Instead they will be
The company has set up a technology
gold is going to increase due to
operating this equipment remotely or
and innovation department that looks
additional development, ventilation
from surface. These are the questions
at near-term, mid-term and long-term
and cooling costs.
mines have to ask themselves,”
solutions in terms of improvedsafety, re-
Holland ponders.
duced costs and increased production.
“With that in mind, we are looking
He says there are several reasons be-
“We won’t be inventing new technolo-
more profitable. How do you take low-
hind this. “First of all, we need to mecha-
gy but will look at technology available
er-grade ore bodies and make them
nise mines to improve safety, because if
on the market, which has already been
more profitable? You change the way
you can take people away from the ore
developed, and that is on the shelf and
you exploit them through innovation
face, they are not exposed to rock falls.
can be used,” says Holland.
and new technology. One can find bet-
We have to think hard about how peo-
“There is technology out there that
ple are going to be deployed. Second,
we can use already, such as the ability
at different ways to make our mines
ter ways to explore, using drones to fly over vast areas of ground and actually
to operate an impact breaker or rock
photograph the whole area. It provides
breaker underground remotely from
quick information that can be fed into
surface. That is a great initiative. It
real-time systems to offer much quicker targeting of ore bodies at much lower cost when we get into an area that we want to mine.
View from atop the processing plant at South Deep
10
which would require no people
Ins i de Mi n i n g 0 6 | 2 0 1 7
“I think it is realistic to say that it will take five to seven years to get to autonomous mining.”
alleviates people from having to travel underground as well as exposing them to the tough environmental conditions. Let us embrace that kind of technology, because it is available,” he adds. Holland says that mechanisation is the industry’s holy grail. “If you can’t improve production through mechanisation, then don’t do it.
gold fields
Mechanisation isn’t just done because
than some of the mines around us. The
around 145 000 oz a year up to about
it feels good – it is done because it is
fixed costs are fairly high, like labour,
225 000 oz a year at lower costs.
going to give a return on investment.
electricity and power. Then there are
Certain mines can only be mined on a mechanised basis. For instance, at South Deep, we mine between
“That will drop our sustainable costs for
consumables, which are semi-variable.
the operation from the current level of
Around 70% of the costs are fixed.
about $1 200 an ounce to about $700
“Every extra tonne that you mine,
an ounce in three years. The initial life
20 m and 100 m ore packages on a
and every extra ounce that you get
of mine is eight years, but as we do the
horizontal plane. If you look at the
comes at a lower marginal cost, which
push back of the pit, it could expose
conventional mines in West Wits, they
means you are able to increase the
more ore body with the potential
are mining 35-degree narrow reef
profitability of the operation by driving
of doing another 10 to 12 years of
tabular ore bodies where the reef is
the volume. All the work that we have
mining, which we are quite optimistic
anywhere between 1 m and 2 m thick.
focused on aims to open up more of
about. Even after that, the ore body
These operations are very difficult to
the ore body and to access a greater
is expected to be open at depth. The
mechanise due to the geometry of the
part of it through development so that
potential for an underground operation
ore body.”
we can increase production volume.
down the road is possible. Work on the
We’ve put out a plan for how the
Damang project started in January
mechanisation is automation. “You
volume will increase over the next five
2017,” explains Holland.
have to go through the steps to get to
to six years until we achieve a steady
automation. I think it is realistic to say
state of production of 500 000 oz a year.
Future plans
that it will take five to seven years to get
Last year, we produced 290 000 oz,”
“We are going to continue to drive the
to autonomous mining.”
says Holland.
longevity of our operations through
He adds that the next step after
brownfields exploration and we are
South Deep
Ghana
South Deep, which is Gold Fields’ only
The major expansion project in Ghana
also going to do more exploration work
remaining project in South Africa,
is a reinvestment of the Damang pit
at our Ghanaian operations. There
turned around from a cash deficit of
at the Damaong mine – an open pit
are a lot of opportunities around the
$80 million in 2015 to $12 million positive
that was mined previously. That is
mines. Apart from the South Deep
in 2016 on the back of a significant
going to mean moving a lot of waste
ramp-up, another significant project
increase in production.
material to access the ore body. “We
for the future of Gold Fields is Salares
will move about 165 million tonnes
Norte in the Atacama Desert in Chile,
profitable is to increase the volume.
over eight years, of which 32 million
at 4 700 m altitude. It is a gold and
This is a bulk underground mine, so the
tonnes will be ore. And that will take
silver project that looks very exciting,”
grade is about 5.5 g, which is lower
that operation from its current level of
concludes Holland.
South Deep's backfill distribution plant
South Deep’s processing plant
“At South Deep, the way to make it
doing a lot of that in Australia. We are
In sid e M in in g 0 6 | 2017
11
gold fields
Damang’s reinvestment plan The Damang Gold Mine in Ghana is being given a second life through a reinvestment plan announced by Gold Fields in October 2016. This will extend the life of mine by eight years, resulting in a 72% increase in gold reserves.
T
he total capital expenditure for
the two mining contractors to access the
the project is US$340 million with
base of the existing pit, and access to
operating expenditure for the
the high-grade Tarkwa Phyllite lithology.
life of mine estimated at about
$1 billion. Not only will the plan enhance
Mining methods
its presence in the area, it will also
At total of 165 Mt will be mined and
benefit the country economically by
32 Mt processed at a grade of 1.65 g/t.
preserving and creating 1 850 jobs.
This will result in estimated gold produc-
“The country will also benefit from
tion of about 1.5 Moz, and an average
royalties and taxes of over $120 million,
annual production of c.225 koz and AIC
education will benefit with about
of $950/oz over the life of mine. Conven-
$1.5 million, health with $0.2 million,
tional open-pit mining methods will be
water and sanitation with $0.7 million,
used, while standard truck-shovel opera-
agriculture with $1.6 million, and
tions will be employed to load and haul
infrastructure with $1 million, all directly
the material with excavators in backhoe
linked to the reinvestment plan,” says
configuration. The ore will be hauled by
Nick Holland, CEO, Gold Fields.
a fleet of 51 dump trucks, each with an
Both the eastern and western walls of
average payload capacity of 91 tonnes.
the Damang Pit Cutback (DPCB) will be
The stockpiled ore will be reclaimed with
cutback dramatically, deepening the
tipper trucks to the processing plant.
pit to 341 m. This will comprise a 265 m prestrip for vehicles and equipment from
The Damang Pit Cutback project will increase the life of mine by eight years
Bulldozers, graders, water trucks and service trucks will also be used in road
gold fields and bench maintenance, and dust and
of the mine is the major capital invest-
erosion control.
ment and need to sustain the long-term
Optionality studies Production from the Damang pit ceased in 2013 amid a variation in grade that made economically viable mining difficult. Ore from other pits was sourced to keep the mine going. Optionality studies were undertaken during 2015 and 2016; the options considered were to continue mining at break-even levels, expand the
ounce profile. The strategy involves: • implementation and monitoring of the approved reinvestment plan • fit-for-purpose structure and continuous improvement initiatives • implementation of a transition plan to
executives to improve productivity/ efficiency gains • development of a sustainable wage model to guide future wage adjustments. The fourth risk is increasing input and capital costs. To combat that, the mine will implement: • efficiency and productivity
contractor mining • modelling of the impact of the Devel-
improvements
opment Agreement on the life of mine
• cost leadership and containment
and mine’s exploration potential.
• implementation and monitoring of the approved Damang reinvestment plan
project, place the project in care and
The second risk involves power and
maintenance or close the project.
switching to backup power
The fifth risk is the potential loss of social
generation and the impact of costs.
and environmental licence to operate.
the reinvestment plan and to continue
The strategy involves:
The mitigation plan involves:
the life mine for another eight years. The
• implementation of a power purchase
• medium- to long-term strategic plan-
“The decision was then made to go for
reinvestment study was reviewed by
agreement with Genser Energy
ning for community investments
external experts and the open-pit mining
• having processes in place to ensure
is being undertaken by local and global
project deadlines and deliverables
environmental authorities and third-
mining contractors. The construction and
are met
party consultants regarding viability
expansion of the tailings storage facilities were the only major civil works that had to be undertaken, and a new SAG Mill shell will be required for the Damang processing plant,” explains Holland.
• Tarkwa and Damang: Commissioning of Genser power plants completed in Q4 2016
• continued engagement with
of tailings raise • all necessary permits and authorisations obtained from
• monitoring of Genser tariffs to
minerals commission.
ensure they are on par or lower than
“The initial life of mine is eight years, but
regulated levels.
as we do the push-back, it may expose
Risks
The third risk centres around wage nego-
the potential of doing another 10 to
According to the company’s 2016 an-
tiations. The mitigation plan involves:
12 years, which we are quite optimistic
nual report, the following is a description
• transparent wage negotiation
about. Even after that, the ore body
of its mitigating strategies for the top five risks of the reinvestment plan. The first risk
could open up at depth. The potential
processes • working with employees and union
for an underground operation down the road is possible,” says Holland.
8 years Life of mine
165 Mt Materials mined
32 Mt Materials milled
1.65 g/t
$16.25/t
Head grade
Processing cost
$700/oz AISC
$950/oz AIC
1.55 Moz
$341m
Gold production
Project capital
$3.60/t
28%
Mining cost
IRR at $1 200/oz gold
In sid e M in in g 0 6 | 2017
13
wescoal
Contributing positively to transformation Trying to create a black-owned business that operates successfully and plays a leading role in the consolidation of the coal sector are two of Wescoal’s targets. The company also wants to add value to a broad range of stakeholders. By Mientjie Kleinhans
B
y achieving this, the compa-
Eskom contracts. “It is also important to
environment in which it op-
ny will contribute positively to
note that the company isn’t prioritising
erates,” says Sulaiman.
the country’s transformation
black ownership or BEE transaction just
agenda as well, according to
for the sake of Eskom. We are doing it
Challenges in coal mining
Waheed Sulaiman, CEO, Wescoal, as he
because we want to create a black-
One of the challenges in coal min-
talks about the company’s 59% transfor-
owned business that is successful and
ing is to be profitable. “If it is not, then
mation deal, its secrets to success, and
it is about good business decisions,”
coal mines will cease to exist. One of the
its flagship mine, Elandspruit.
explains Sulaiman.
ways where we see ourselves playing a
The 59% transformation deal was
role is through consolidation. We believe
finalised in December 2016, with one
Recipe for success
of the key points being that the 59%
For Sulaiman, the secret to success is
that space, we can reduce the cost of
black ownership is locked in for the next
teamwork – being surrounded by the
extracting coal. That is one area that we
five years. “Within the next five years,
right team, believing in the same vision,
think we can play a role in meeting one
more than 50% black ownership
and working towards the same end
of the challenges in the coal space in
in Wescoal is guaranteed. We
that through consolidation and growth in
goal. Further, it is also about looking
South Africa,” says Sulaiman. Another challenge is that mining is de-
created a special purpose
at the business holistically and iden-
vehicle and injected these
tifying where to add value to not
structive to the environment, and coal
black shareholders into that
only one group of stakeholders, but
mining is no different. “One has to be
vehicle, called the SPV,” says
to a broad stakeholder base. “The
able to manage that effectively, and
Sulaiman. Although the deal
stakeholder base includes
work towards having a positive impact
was finalised in 2016, not
communities, employ-
on the community and society within
many of the details have
ees, shareholders,
the country where the mines operate.
been revealed yet. Another important aspect for the com-
and regulatory authorities. It is about looking at the
After mine closure, society and the community should be better off. It shouldn’t be a case of businesses just taking the
pany is its Eskom
company in its
resources and moving on. Working with
contracts, which
broader context
and developing communities will help
are also signed
and how it fits
with the economic inequality and trans-
for five years. The
into the com-
formation issues in the country as well,”
Eskom agreements
munity and the
says Sulaiman.
require that Wescoal be more than 50% black owned, so the BBBEE transaction guarantees the life of the
It is in challenging times that you find your value as a person and a business.” Waheed Sulaiman, CEO, Wescoal
wescoal The Elandspruit processing plant
Wescoal’s commitment to the community includes building a new access road
One of Wescoal’s rehabilitation projects, of the Blesbokspruit, started in December 2015 and ended in October 2016
Flagship project
themselves well to increased produc-
economy.. Lots of understanding and
“When Elandspruit was originally
tion, as long as we can find a customer
dialogue, identifying specific deliverables
conceived, we expected to mine about
prepared to pay a suitable price for
and working towards them, and holding
160 000 t per month. We are mining now
the coal and provided we can process
each other accountable are the foun-
close to 200 000 t per month, and that
as we need to. Then we can ramp up
dation and building blocks for the way
is just because of various improvement
production easily.”
going forward.
way. We also increased the production
Trust and communication
industry and the country as a whole, but
with the feed capacity of the processing
Sulaiman believes that for government
I do believe it is in challenging times that
plant. When we increase that capacity,
and the mining industry to work together
you find your value as a person and a
we can increase the production of the
and uplift the economy, there has to be
business. You come out stronger at the
mine, since the systems are linked,”
a level of trust between the parties as
end,” says Sulaiman.
explains Sulaiman.
a starting point, followed by high levels
projects we implemented along the
“It is a challenging time for the mining
of communication. “Both need to un-
Future of coal mining
better than expected and Wescoal
derstand each other’s challenges and
Sulaiman concludes the interview with
has also identified other areas of
objectives. Once you have a good un-
his view of the future of coal mining in
growth within the mine itself to increase
derstanding of that, even if there is disa-
South Africa. “Coal is a cheap source of
production even further. The compa-
greement, you can at least work towards
energy; however, it has both negative
ny will announce those plans quite
common objectives.
and positive attributes. The country
He adds that the mine itself is doing
needs energy to grow and develop and
soon. “The resources are good, and
“I don’t think the two groups neces-
the average strip ratio of the life of
sarily need to agree on everything, but
it is my view that coal forms part of the
mine is approximately two. The open-
there is common ground to be found
energy mix for the country, and it can’t
pit reserves are fairly shallow and lend
if both have the objective to grow the
be completely ignored.”
In sid e M in in g 0 6 | 2017
15
wescoal
The new slew conveyor is the latest addition to the processing plant
Taking Elandspruit
underground Moving the Elandspruit operations underground has always been a part of Wescoal’s original mine plan. The underground operation started early this year and the team has been ramping up production as of May 2017. By Mientjie Kleinhans
W
an operational coal mine. Wescoal is mining from that access point into Elandspruit’s own reserve and will be using a room-and-pillar approach to mine the reserves using a continuous miner.
Slew conveyor “Last year, we signed a number of export contracts, which increased our
hile the commissioning
balance, as the open-pit operations
exports to about 1 million t per annum.
of underground operations
have a lower operating cost base than
One of the improvement projects at
at Elandspruit has com-
the underground operations. We need
our processing plant to support these
menced and is producing
to achieve a balance throughout the life
new contracts was the installation of
about 10 000 t a month on average,
of mine,” says Thivha Tshithavhane, CEO:
a slew conveyor to handle sized coal.
production has been ramped up to pro-
Mining, Wescoal.
The main challenge we face now is
He adds that the main focus for now is
duce 20 000 t a month. “At the underground opera-
the optimisation of yields and saving
to look at the yields and increase profit
costs, which will be the focus this year,”
margins. “The production is coming. We
says Tshithavhane. The main plant was originally bought
tions, we will be
are at full capacity at the processing
mining Seam 1
plant and at the mine. So how do we
in 2014 to beneficiate coal produced
Upper, which
make more money? We have to be
for the local market from the compa-
is of a better
more efficient and effective in what we
ny’s Elandspruit Mine. During 2015, var-
quality than
do,” says Tshithavhane.
ious de-bottlenecking and upgrading
the open-pit reserves. We will have to strike a
The underground workings will be
projects were undertaken, and by the
accessible through a decline shaft
end of Q3 2015, the plant was ready
from the neighbouring Nungu Colliery,
to fulfil Wescoal’s planned contractual supplies to Eskom power stations.
The main challenge we face now is the optimisation of yields and saving costs, which will be the focus this year.” Thivha Tshithavhane, CEO: Mining, Wescoal
During the second week of September 2015, soon after the first short-term agreement between Wescoal and Eskom was concluded, the first product was dispatched to the power utility, in accordance with contractual specifications. Since then, Wescoal and
wescoal wescoal Eskom signed four more extensions to the original agreement. An additional, smaller plant processes product for power stations, as well as nuts, peas, grains, duff and fines. This plant processes over 12 000 t/month of various products for the local market.
Background Mine establishment activities at Elandspruit commenced on 4 June 2015, with originally planned volumes of 130 000 t to 150 000 t of ROM coal per month – equivalent to about 1.8 million t/year of ROM. With
All material less than 0.5 mm is piped to slurry dams The Elandspruit processing plant will process material from all three mines
the additional processing capacity now installed, the ROM could be increased to more than 200 000 t/month, or 2.4 million t/year. A mining contractor takes care of all the mining operations at Elandspruit – from topsoil removal, drilling, blasting and excavating to stockpiling into various product piles. To do that, the mining company makes use of five 100 t rigid trucks, six 40 t and six 50 t articulated trucks, and seven excavators, graders, dozers, and water trucks.
Slurry dams From the process plant, all material less than 0.5 mm is piped to slurry dams. There are three slurry dams that allow the solids to settle, thereby allowing the water to drain into the main return water dam. The water in the slurry dams is filtered through a layer of gravel before it filters through pipes with minute holes. From here, the water is treated to be useable when it reaches the fourth and final dam. Although not potable, the water is clean enough for the operation. The water is contained in a closed-loop circuit and make-up water comes
Facts & figures 12 to 15 years life of mine Located outside Middelburg, Mpumalanga Open-pit and underground operations ROM reserves of about 27 million tonnes
from mined-out, polluted water that is treated for the processing plants.
Khanyisa Another mine using the Elandspruit processing plant
The open-pit and underground operations will have to be balanced throughout the life of mine
is Khanyisa, which resumed operation in May. Soon, all three mines – Elandspruit, Khanyisa and Intibane – will be operating at full capacity and supplying the Elandspruit processing plant as required.
Future plans “We have publicly stated that we want to produce more than 8 million t/year of coal in the short to medium term and we want to play a leading role in the consolidation of the coal space. We want to acquire other mines, other businesses and resources, and that will inevitably mean that the company is going to grow. We are on a journey to becoming a much larger business than we are now,” concludes Waheed Sulaiman, CEO, Wescoal.
In sid e M in in g 0 6 | 2017
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chamber of mines
g n i k c a r t Fast n o i t a s i n er d o m
As the world grapples with the fourth industrial revolution, so the South African mining industry is grappling with its own revolution – quietly, inexorably, and more swiftly than one might think.
T
his picture gels with the words
the gold and platinum sectors.
of Neal Froneman, vice-president,
Essentially, 2016 was a year of
Chamber of Mines, at the recent
formulation, whereas 2017 is the
Investing in Africa Mining Indaba,
when he said: “The South African mining industry is one of great contrasts – in some cases needing to be dragged, seemingly reluctantly – into the 21st century and beyond, and in other areas, leading the way.” Talking to Inside Mining, Sietse van der Woude, senior executive: Modernisation and Safety, Chamber of Mines, says: “After the Mining Phakisa Lab in 2015, considerable progress was made by the chamber’s Modernisation Team in 2016 to establish ‘quick-win’ research
The quick-win programmes are divided into:
• t hose affecting current mining operations •m echanised mining year of implementation.” •n on-explosive rock breaking Some of the achievements • t hree cross-cutting initiatives: of 2016 include the agreement •a dvanced ore-body knowledge among stakeholders to develop • r eal-time information management systems or digitisation in mining a model based on public-private • t he transition to more modern partnership for the mining cluster, mining methods, systems and mines. founded on the principles of: The Just Transition programme is a • open innovation particularly important framework • commitment by the Department that encompasses a range of social interventions needed to secure jobs of Science and Technology to the and livelihoods when economies are reestablishment of the CSIR site shifting to sustainable production. at Carlow Road for collaborative mining research • the establishment of the Mining Equip-
and development (R&D) programmes
ment Manufacturers of South Africa,
that will ensure delivery on user-based
as a Cluster Development Programme,
R&D requirements. These requirements
supported by the Department of Trade
The year also saw the development of
and Industry
detailed charters for the seven quick-win
have been clearly articulated in terms of solutions that are required to ensure the sustainability of the industry, especially in
• the awarding of a budget of R150 million in government funds
over three years in the Mid-Term Budget Statement.
programmes as the core of the R&D programme by the mining industry, through
In sid e M in in g 0 6 | 2017
19
chamber of mines
mining companies. Assuming it is the latter, the aim of this initiative is to illustrate to mining companies what South African
the Chamber’s Innovation Team, as well as the securing,
including mining companies,
entities can do through innovation to
suppliers of goods and services,
help them deal with the difficulties they
research and development
encounter. Almost daily, we come across
entities, government, and funding
new companies whose challenges could
agencies. Research and stakeholder
be solved through mining. By mapping existing ecosystem efforts, designing to
in principle, of an agree-
engagement will
enhance what exists and then generat-
ment on a test mine fa-
be undertaken on
ing interest through events, the intent is to
cility, which will be open
trends, scenarios
develop a comprehensive understand-
to all participants.
and decision points
ing of the mining innovation ecosystem
around technology,
across South Africa, together with a
grammes are based on
society, regulations
means to activate that ecosystem to be
industry needs, as well as
and innovation.
fully effective.
national needs, with the
The roadmap
aim of improving the
should provide a
Funding and governance models: The
contribution of the min-
holistic view of the
main aim of this project is to provide
ing sector to the econ-
multiple futures of
guidance on possible public-private
omy on a sustainable
South African mining,
partnership funding and governance
and inclusive basis.
together with the
models that will accelerate mining
Looking forward,
decision points that
innovation in a holistic manner.
The quick-win pro-
things are going to
could enable the
get even more excit-
country’s mining to
Just Transition programme: As part
ing, says Siets.
choose ‘better’ futures.
of a people-centric approach to introducing technology and other
The Chamber’s priorities for 2017 are as
‘Rebooting’ the mining
forms of innovation, the transition to
follows:
innovation ecosystem:
modernised mining needs to be just and
South Africa used to be
socially acceptable. The impacts of
Developing a 2030 Mining
considered among the
innovation need to be communicated
Innovation Roadmap: Mining
global leaders in mining
by parties that enjoy credibility among all
companies are the end users of
innovation, but this is no
stakeholders and then be addressed in a
innovations aimed at addressing
longer the case. The ques-
holistic manner.
all the challenges they face
tion is whether the mining
from technical, safety, health,
innovation ecosystem is
For more information, take a look at
skills development, environment
‘broken’ or lacks visibility to
www.mine2030.co.za
and societal expectations. The aim of the 2030 Mining Innovation Roadmap is to provide direction to all those involved in mining innovation,
20
Ins i de Mi n i n g 0 6 | 2 0 1 7
Essentially, 2016 was a year of formulation, whereas 2017 is the year of implementation.” Siets van der Woude, senior executive: Modernisation and Safety, Chamber of Mines
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Fossil Fuel Foundation
Effectively capturing
F
coal emissions or this reason, it is vital to understand the problems concerning the
use of coal and to use methods that ensure it is used wisely and cleanly. A number of approaches will be outlined in due course,
Coal is under threat in many areas from the global climate change community, from organisations and bodies that have little time for the benefits of the greatest mineral-based energy asset in the region. By Professor Rosemary Falcon*
but one of the surprising
The conference was hosted by the International Energy Agency Clean Coal Centre (IEA.CCC) and was entitled the Mercury and Emission Conference (MEC) 2017. Studies were presented outlining the international limits of
matters recently brought
various emissions from
to light was the presence of mercury in
that mercury was being transmitted
coal-fired power generating plants now
coal and the tightening legislations now
from the industrial site into the waters
being proposed and – more importantly
being promulgated in many countries
of the bay that supplies the villagers
– methods of capturing those emissions,
of the world.
with their fish. The Minamata Conven-
including mercury.
This all began with the events that
tion was then established and various
took place in a small fishing village in
countries around the world joined
Mercury
Japan. Many inhabitants of Minamata,
this association.
One of the most important studies in
a village situated near an industrial site,
A recent conference of the Minamata
relation to South Africa arose from Pro-
developed cancer and children under-
Convention members was held at the
fessor Panichev at Tshwane University
went abnormal growth patterns, which
Kruger Gate Hotel, which was attended
of Technology in Pretoria, who showed
led to an investigation. This revealed
by 70 international delegates including
that mercury occurs in various forms,
Pretreatment of coal in the form of beneficiation at the mine face can be highly beneficial to the reduction of mercury in coals
22
the Fossil Fuel Foundation.
Ins i de Mi n i n g 0 6 | 2 0 1 7
Fossil Fuel Foundation both as absorbed elemental mercury and mercury bound to pyrite. His work indicates that pretreatment of coal in the form of beneficiation at the mine face can be highly beneficial to the reduction of this element in mercury-containing coals. This would lead to the reduction of
coal-fired emissions reduction in that this
Minamata Convention
This global treaty aimed at protecting human health and the environment from the adverse effects of mercury was adopted on 10 October 2013 in Kumamoto, Japan
process reduces SOX from pyrite – the
To read more www.mercuryconvention.org
absorbents with coal during the com-
most plentiful greenhouse gas – and
consequently mercury within the combustion bed (IN-BED). This occurs through the burning of bustion process and does not require
high-ash and pyrite-containing materi-
water, as is the case with many FGD
als. Fortunately, South African coals gen-
processes. This combustion process also
erally contain low pyrite concentrations
produces zero to negligible NOX emis-
due to the nature of the origins of the
sions, the second major greenhouse gas
region’s Gondwana-type coals. Howev-
IN-BED, due to the low temperatures in
er, caution is advised when using high
the CFBC process. South and Southern
sulfur-containing discarded materials
Africa, in such cases, will be well situ-
from wash plants (discards) where pyrite (high sulfur) could be concentrated. Another speaker at the MEC 2017 conference provided the answer to the
ated to manage their greenhouse gas of limestone (calcium-containing material) and SOX to form gypsum, a valua-
and mercury emissions in this manner. CO2, a separate emission gas, will be
ble building material. This same process
discussed in the future.
capture of mercury in post-combustion
has been found to capture mercury by
processes, namely in the flue gas desul-
adsorption of the oxidised mercury in
furisation (FGD) process, which captures
the flue gas of power stations. This rep-
SOX, a greenhouse gas that needs to
resents a major co-benefit.
be reduced from coal-fired power gen-
The future use of circulating fluidised
eration plant in the future. This capture
bed (CFBC) boilers in the Southern Afri-
occurs through the chemical reaction
can region bodes exceptionally well for
*Professor Rosemary Falcon is from the School of Chemical and Metallurgical Engineering at the University of the Witwatersrand, and the Fossil Fuel Foundation.
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Following successful local and international previews, worldwide sales of Bell Equipment’s eagerly anticipated E-series large trucks have commenced and reinforce the OEM’s commitment to the mining industry.
I
ncorporating the latest in articu-
According to Tristan du Pisanie, prod-
lated dump truck (ADT) design and
uct marketing manager, Bell Equip-
technology, the Bell E-series large
ment, the B60E has also generated
trucks are the culmination of three
great interest. “While the Bell B60E is
and a half years of development and
able to run alongside rigid trucks with-
testing, and represent an evolution of
in the 60 t to 80 t class, the concept
the D-series range, which has set industry
is ideally targeted for mines, quarries
standards and led ADT innovations for
and bulk earthworks that experience
over a decade.
conditions rigid dump trucks cannot
The E-series range was launched three
safely cope with, such as rainy periods
years ago, with the smaller B25E and
that compromise underfoot condi-
B30E. The large trucks add five new
tions. When traditional 4 x 2 rigids can
models: the B35E, B40E, B45E, B50E and
no longer operate, the superior 4 x 4
the innovative 4 x 4 crossover concept, the B60E. Bell is particularly buoyed by its
clockwise from top left During comparative testing between the B40E and the B40D, it was found that – taking into account all of the variables – the B40E will deliver a 6% to 7% lower cost per tonne to Bell customers than its predecessor With the exception of the B35E, all the Bell E-series large trucks are fitted with the Allison 4700 transmission with seven gear ratios for better grade ability with reduced fuel consumption With its rated payload of 41 000 kg, a bin volume of 25 m³ and a powerful new engine, the B45E has the potential to become the most popular model in the range due to its overall value proposition to customers
traction, oscillation-tube and retardation characteristics
needs, it will be fitted with an Allison
of the Bell B60E pay off by
transmission and powered by the new
45 tonner in light of increased
keeping production going,
Mercedes-Benz HDEP engine platform,
global demand for this truck size.
which is a huge opportunity
optimised for off-highway use by MTU.
With its rated payload of 41 000 kg,
for many customers.”
a bin volume of 25 m³ and a pow-
Whatever Bell large truck
platform has been in production at
a customer chooses to best
Mercedes-Benz for seven years. It is
erful new engine, the B45E has the potential to become the
meet their business
to its overall value proposition to customers.
an engine that Mercedes-Benz is very familiar with and we are confident that
most popular model in the range due
“While new for us, the HDEP engine
Tristan du Pisanie, product marketing manager, Bell Equipment
our customers will appreciate the advances in terms of fuel economy and power density over our D-series machines,” says Du Pisanie.
In sid e M in in g 0 6 | 2017
25
earthmoving equipment
ADT for all conditions
A
The TA300 can perform a variety of functions on a single project
n articulated dump truck
speeds, and operate at lower costs as a
under extreme working conditions,”
(ADT) that is compact and
result of their fuel-efficient engines.
says David Vaughan, sales director:
versatile, and ideal for light
“The TA300 is a tough, rugged and
Equipment, Babcock.
mining and construction
versatile machine that, with permanent
An additional feature of the truck is
applications, is the Terex TA300. This
six-wheel drive, can operate in the most
that it does not require a diesel particu-
truck’s versatility and fuel-efficient
challenging environments. The 28 t
late filter (DPF), reducing maintenance
engines have made it popular in
payload capacity and ease of mainte-
time and cost, and fuel consumption.
various industries.
nance of the truck makes it a perfect
The engine is a five-cylinder, in-line,
match for both light mining and con-
four-cycle, water-cooled, turbocharged
anywhere – from hard surfaces to wet
struction applications,” says Erik Lund-
air-cooled, direct-injection system with
and muddy conditions – and is ideal
berg, business manager: Sub-Saharan
electronic engine management.
for quarrying, light mining, earthworks,
Africa, Terex Trucks.
The Terex ADT can operate just about
civil construction and general
The truck is also equipped with true
To allow all terrain travelling in any weather condition, the trucks are fitted
construction. Therefore, the truck can
independent front suspension as
with heavy-duty axles with fully floating
perform a variety of functions on a
standard to enable traction control
axle shafts, and the three axles are in
single project while operating in diverse
and operator comfort. “The truck is
permanent all-wheel drive. Adding
underfoot conditions.
designed with the customer and oper-
to that are the three axles that have
With payloads of 28 t and powered by
ator in mind, and offers straightforward
hydraulically actuated multiplate
Scania engines, the trucks are able to
solutions to the toughest challenges,
transverse diff-lock differentials for total
increase production due to higher top
with the ability to operate efficiently
cross-axle lock up.
FEEL THE EARTH MOVE ... TAKRAF Africa is a key supplier of equipment and systems for surface mining and bulk handling solutions. From excavation and comminution, environmental control, conveying and stockyards, through to loading and unloading, we have the systems and expertise. Including spares and support with locally based in-house maintenance teams, specialised technicians and engineers.
TAKRAF Africa 96 Loper Avenue, Aeroport, Spartan Kempton Park, 1619, South Africa T: +27 11 201 2300 takraf.afr@tenova.com www.takraf.com
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End-to-end cybersecurity
EcoStruxure for industries
Apps, analytics and services
Driving operational efficiency • Connectivity for data that maximises asset utilisation • Resource-to-market integration for business efficiency • Enhanced safety and security
Mine/Pit
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Scan the QR code to download a FREE copy of the Mining, Metals & Minerals brochure & discover how you can get the most from your mine.
www.schneider-electric.co.za In sid e M in in g 0 4 | 2017
27
Transport & Logistics
Making transport
safer
Mines have become very conscious of safety, with one area of concern being the safe transport of material. While mining companies strive for increased production by moving materials faster, the issue of safer transport has become a trending topic. By Tristan du Pisanie
T
28
trucks safer to operate than others. In soft underfoot conditions, for example, an articulated dump truck has better traction than a rigid truck. When obtaining a fleet of trucks, mines need to look at their productivity requirements and site conditions in both good and poor weather conditions.
Contractors In many cases, mines outsource their transportation and logistics requirements to contractors. It is important for mines to be aware of the type and state of their fleet, not just the best-priced quotes, before signing any contracts with contractors.
here are a significant number
as possible. Of course, the downside
of things mines can do with their
to having fewer machines is the higher
contractor in the industry, it is worthwhile
of transport fleet to promote
capital investment and the cost of site
investigating how they've achieved their
safety on mines. To ensure the
infrastructure, which needs to be suffi-
competitive advantage and whether
safe transport of material, mines should
cient to handle larger machines. Properly
this represents sound business practice.
investigate the best truck fleet for the
trained operators are also critical to safe
In the current economic environment,
job according to site conditions and the
transport and, for this reason, many OEMs
tendering is particularly competitive
productivity that they need to achieve
like Bell Equipment offer operator training
and mines need to be cautious of com-
from their fleet.
through accredited training centres.
panies using older machines, which
The main principle of safe operation
Underfoot conditions affect site safe-
is to have as few machines operating
ty as well, and definitely make certain
Ins i de Mi n i n g 0 6 | 2 0 1 7
If someone undercuts an established
allow them to run cheaply, or using new machines that they won't be able to
Tristan du Pisanie, product marketing manager, Bell Equipment
weighing – which has been offered on
operator applies pressure to the
Bell ADTs since 2002 – are key tools in
accelerator pedal.
combating the overloading of trucks.
Downhill Speed Control, a feature of
Statistics of the average payload enable
Bell trucks since 2008, automatically var-
a fleet owner to ensure they are not over-
ies retardation to keep a vehicle at a set
or underloading. Bell also offers load lights
speed (the speed at which the operator
maintain properly at the quoted rate.
as an option, which indicate to the exca-
takes their foot off the accelerator pedal
It is also important to keep in mind that
vator operator and site supervisor wheth-
or brake pedal) while going downhill.
availability will be compromised on older
er a truck is optimally loaded or not.
This allows the operator to focus on
machines and productivity will be nega-
Bell ADTs pioneered a number of safety
steering without having to worry about controlling speed.
tively impacted. Similarly, if a contractor
features in the industry for facilitating
is running new machines into the ground,
safe machine operation, and have
vehicle operation won't be sustainable
numerous safety features as standard.
B60E, Bell has additionally introduced an
over the medium to long term.
Safety is a major consideration during
automatic Hill Hold, whereby the brakes
the design process of these ADTs, which
are automatically applied if the operator
are meant to lead the field through the
takes his foot off the accelerator pedal
integration of the latest technology.
while driving up an incline to prevent the
Size does matter As a general rule, using bigger trucks results in lower costs per tonne to cus-
Tip Safe, which Bell introduced in 2010,
With the introduction of the B35E to
truck from rolling backwards.
tomers. The cost of a running machine
has proved to be a safety feature that
When the accelerator is activated
includes operator salary, maintenance,
customers really value, as well as a key
again, the brakes are released when
fuel and tyres. With larger machines, all
factor in securing deals in a number of
there is enough engine torque to pull
of these costs become more expensive
instances. The Tip Safe feature prevents
away smoothly.
(with the exception of the operator sala-
the tipping of the bin when it is unsafe
There is also the company's proprie-
ry); however, the percentage increase in
to do so. Due to the oscillation joint, it
tary satellite fleet management system,
these costs is generally lower than the
is possible for an operator to reverse a
Fleetm@tic, which provides productivity
percentage increase in payload and
truck such that
productivity of these trucks.
the rear chassis
Overloading Although most mines are quite conscious of loading trucks correctly, it is still im-
is leaning over precariously while the front is level. A second
The main principle of safe operation is to have as few machines operating as possible
and machine data. With safety in mind, Fleetm@tic enables fleet owners to geofence areas so that a truck can have
portant to remember that overloading
feature,
trucks could lead to early failures, while
Neutral Park Brake, was introduced in
enforced within a demarcated area.
underloading would suggest a fleet
2009 and negates the risk of a truck
Within a hopper site, for example, the
owner is not fully benefiting from the
rolling away when it is put into neutral
truck may be geofenced to travel at a
machine. By exceeding the design pay-
and the operator takes his foot off
slower speed. It also helps to plan ser-
load, a truck's systems (such as brakes)
the brake pedal, particularly when
vicing and preventative maintenance
are operating outside of the safety spec-
the truck is parked on a slope. The
as well as corrective operator training,
ifications of ISO standards, which can
ADT automatically applies the park
which all impact on safety.
become a hazard.
brake when neutral is selected and
a specific speed limit
With so much technology on the mar-
There is actually no excuse to over-
automatically releases it when the
ket, there are no more excuses to trans-
load trucks. Telematics and on-board
transmission is put in gear and the
port materials unsafely.
In sid e M in in g 0 6 | 2017
29
Transmissions, Gears & Motors
More than
energy-efficient motors Energy-efficient motors are only one component in the holistic picture of saving energy in the mining industry. Even though a motor may be labelled as energy efficient, it doesn’t necessarily result in energy savings if it is not operated at its optimal point. Norman Maleka* discusses all the criteria.
M
ines are not the most efficient operations in
pulleys, bells, chains, and many
energy saving. They are
more components can have multiple
aware of the value of energy saving,
suppliers providing each element. All
and they know about cost cutting.
of these elements need to be looked
Even though they are aware of all these
at individually to see how the system
measures, there is still much that can be
can integrate everything in such a way
done to save energy.
that it contributes to energy efficiency. or changing lubrication intervals may
term energy solutions, despite the fact
be all that is needed to realise the
that they are aware of the energy-
savings required from that activity.
As a supplier and OEM, we try to
One method of saving energy is to look
energy by looking at the system
at the control of the motors, and also
holistically, and not only purchasing
to add a variable-speed drive (VSD).
an energy-efficient motor to place in
When a motor starts up – when it is
thinking that the motor alone will save 30% energy. Unfortunately, it doesn’t work that way.
Ins i de Mi n i n g 0 6 | 2 0 1 7
Areas of energy-saving
identify areas where mines can save
an application,
30
Getting rid of some pulleys, or chains,
they will prioritise urgency over long-
saving concepts.
sales manager at SEW-Eurodrive.
A system consisting of controls,
general when it comes to
When mines need something done,
*Norman Maleka is the national
other areas of possible energy savings.
The entire
One method of saving energy is to look at the control of the motors, and also to add a variable-speed drive
switched on – it runs at full speed, pulling a lot of power from the grid. Every time the motor is switched on or off, it pulls more power and, therefore,
system has to be analysed from the
the energy consumption goes up. As
beginning up to the end to identify
energy-efficient as a motor may be,
Transmissions, Gears & Motors every time you start the application, the motor peaks and pulls more energy. But in using a VSD, the start is smoother and does not draw so heavily on the grid. This reduces stress on the motor, which improves its lifespan. There are also mechanical applications to take into consideration.
Measurement Graphs are the measurement that can be taken from data on-site. Our company’s energy consulting service assists mines by going to site, using a log meter and monitoring the system. From this data, we pick up the trend, analyse the data, and then report potential energy-saving solutions to the customer. An energy calculator will assist in comparing IE1, IE2, and IE3 motors with or without a VSD. This comparison will assist, from a theoretical point of view, in determining how much energy can be saved, as well as what the subsequent cost implications. By comparing data such as the cost of energy and the length of shifts, we can work out the savings that can be realised with a particular system. Those are some of the tools that can be used in conjunction with the information from the customer to make an informed decision.
New technology New technology allows motors to be smaller, yet more powerful and efficient. This is achieved through the quality of the materials used and new engineering processes, which also allows them to be more compact and economical. In today’s world, motors have to be light for easy movability, as well as small and compact to fit into difficult spaces, like in conveyors that have limited space.
Optimal point Using motors that are bigger than is actually required to save energy is a myth. For instance, to use a 1.1 kW motor where a 0.75 kW would suffice is not economical. A biggerthan-required motor will not necessarily save energy, it will fulfil the requirements to move the load, but that is not the right way to do it. One only realises energy efficiency when operating at an optimal point with the required power. The optimal point starts at project planning. The customer has to give the consultant the exact data as to how the application is going to work, at what speeds it will run, and how much weight will be moved from point A to point B, and then a decision can be made. The consultant then selects a motor coupled to a gearbox that it is going to operate at a point that will achieve the optimal result. An oversized motor will mean unnecessary money spent, because as you go up in sizes, you spend more money, and you would not end up running at the most efficient point on the graph. Other than saving energy, we want to automate most processes, such as materials handling, but we want to use reliable components. Motors have been around for a long time and they have proven their reliability. There are motors in almost every application in mining, and by looking at the entire system holistically, mines can save energy and costs with the help of professional consultants.
32
Ins i de Mi n i n g 0 6 | 2 0 1 7
Health & Safety
Spray-on liners for gas management
Mining often takes place in inherently trying conditions, so finding innovative ways to establish a safer working environment is a crucial aspect of operations. In underground coal mines, gas management presents an ongoing challenge.
N
China
14 February 2005
Sunjlawan, Haizhou shaft, Fuxin
214
USA
2 June 2006
Sago, West Virginia
12
spray-on liners for gas management in
Kazakhstan
20 September 2006
Lenina, Karaganda
43
underground coal mines’, authors Z Li,
Russia
19 March 2007
Ulyanovskaya, Kemerovo
108
Ukraine
19 November 2007
Zasyadko, Donetzk
80
USA
5 April 2010
Upper Big Branch, West Virginia
29
Turkey
17 May 2010
Karadon, Zonguldak
30
New Zealand
19 November 2010
Pike River Mine
29
China
29 March 2013 1 April 2013
Babao, Baishan, Jilin
36 17
China
12 May 2013
Taozigou, Luxian, Sichuan
28
China
13 December 2013
Baiyanggou, Hutubi, Xinjiang
21
China
21 April 2014
Hongtutian, Yunnan
14
ot only does coal seam gas affect the safety of people underground, it also affects productivity, which can lead
to financial losses and fatalities. In the technical paper ‘Potential use of thin
S Saydam, R Mitra, and D Chalmers review gas management challenges. They discuss the potential use of thin spray-on linings (TSLs) as a gas management tool in underground coal mines. This may involve reducing gas migration
table 1 Major coal mine explosion incidents since 2000 Country
Date
Coal mine
Fatalities
into the excavations/roadways, enhancing in-seam gas drainage, and preventing spontaneous combustion. The authors write that coal mines have to develop effective strategies to control the gas concentration below the threshold value to meet statutory
In sid e M in in g 0 6 | 2017
33
Health & Safety
table 2 Advantages and disadvantages of different gas emission control techniques Technique
Advantages
Disadvantages
Ventilation
• Most common method of dealing with gas emission
• Not effective with high gas emission because of high costs and unacceptable air velocities
• Applicable in mines with low to medium gas emission Gas drainage
• Ventilation capacity may decline due to leakage
•R eliable method for controlling high gas emission in mines
• Needs long drainage time prior to intersection by development road
• Reduces the gas content of the coal seam and shields the development entry
• Limited success in low-permeability coal
• Can capture gas for power generation
• Fractures around the drainage pipe, resulting in air dilution and reduced suction pressure • Cannot deal with irregular gas emissions
Thin spray-on liner (TSL)
• Very low permeability • Can deal with irregular gas emissions
•T SL cannot be applied alone to control gas emission; it has to be applied to supplement other techniques
• Many operational benefits such as rapid application, rapid curing, low volume required • Can bring other benefits such as ground support, spontaneous combustion control, and reducing the ventilation friction factor requirements. Ventilation has been the
the development rate, thus causing sig-
idea of using TSLs as surface support was
first solution in gas management for
nificant economic loss to the coal mining
initiated in the late 1980s in Canada,
underground coal mining. When the
industry,” write the authors.
and was originated by the thought that
emitted gas cannot be effectively dilut-
34
a liner as thin as 5 mm should perform
ed by ventilated air, gas drainage using
Use of TSL
pre- and/or post-drainage has to be
They explain that TSL materials for the
shotcrete. Since the 1990s, TSL support
introduced. “However, even with ven-
mining industry were initially designed as
has become a focus of mining industry
tilation and gas drainage, irregular gas
sealants to limit the weathering of rock,
due to the considerable operational
emissions usually increase the gas con-
and later were intended to be used as
benefits, with the potential to reduce
centration in roadways and slow down
a substitute for mesh or shotcrete. “The
mining costs.”
Ins i de Mi n i n g 0 6 | 2 0 1 7
the same as, or even better than,
Health & Safety table 3 Ideal thin spray-on liner properties and characteristics
reactive TSLs such as polyurethane-, pol-
Property or characteristic
Recommended range
yurea-, or methacrylate-based materials
Non-combustible
Flame spread rating max <200
Tensile strength
>5 MPa
Adhesion strength
>1 MPa (hard rock), >3 MPa - 4 MPa (weatherable ground)
Shear strength
>2 MPa
Curing time
<1 hour
investigate the permeability characteris-
Temperature tolerant
0°C - 50°C
tics of different TSLs, either with or without
Application rate
>1 m2/minute
strate. Among all the TSL materials test-
Pot life
>1 hour
ed, the polymer/cementitious-based TSLs
Cost
<US$20 per m2
recommended for gas management in
Application
Minimal or no surface preparation
Rebound
<5%
are not recommended for underground applications. Most of the products on the market are nonreactive TSLs with modifications to reduce the curing time. Motivated by the potential for using TSLs as a barrier against gas movement, many tests have been conducted to
considering the interaction with the sub-
have the lowest permeability and are underground coal mines from a permeability perspective. “Gas emissions can adversely affect safety and production in underground
They list the most common uses of
• rigid ventilation seals
coal mining. Appropriate approaches
TSLs, and that the applications were
• preventing ground degradation from
and equipment are needed for con-
usually at locations with exceptionally unfavourable ground conditions or
weathering fretting and swelling.
ground control problems:
Summary
• support between rock anchors
The paper reviewed the current gas
• supporting areas with limited access
management challenges and presented
and/or logistics constraints
trolling gas emissions in order to provide safe working conditions. Ventilation and gas drainage are the most important techniques for this purpose. “However, irregular gas emissions will
the potential benefits of TSLs for gas
usually increase the gas concentration
• mesh replacement
management in underground coal
in the roadways and slow down, or
• as primary support immediately
mines. “These may include reducing
even stop, development. To address
gas emissions into the ventilation
this issue, TSLs have the potential to be
system, enhancing the in-seam
used as a ‘cosmetic’ support for sealing
drainage performance, and controlling
the fractured zone and decreasing the
spontaneous combustion.
irregular gas emissions. During under-
after blasting • temporary support (can be covered by shotcrete at later stage, if necessary) • temporary support in TBM tunnels (per-
“Since their introduction, TSLs have
ground in-seam drainage, the applica-
received increasing attention from the
tion of a TSL may prevent gas migration
• reducing rockburst damage
mining industry around the world due
into the drainage holes through the
• pillar reinforcement
to the significant benefits they bring,
fractures near the ribs, thus increasing
• face support
such as low volume, rapid application,
the drained gas purity and gas produc-
• large machine borehole lining and
and rapid curing, with great potential to
tion. Furthermore, the application of TSL
reduce mining costs. However, this tech-
can also help decrease the rib emis-
• stabilisation of return air tunnel
nology is not yet mature and is still under
sions to the ventilation environment,”
• ore pass lining
development. Most of the products on
write the authors.
• prevention of rockfalls caused by un-
the market are still undergoing study and
manent support can be installed behind the equipment)
stabilisation
According to the authors, TSLs have
ravelling, slabbing, or loosening of small
field trials,” write the authors.
the potential for controlling spontane-
blocks of rocks
They add that, for safety reasons,
ous combustion by sealing the leakage path and thereby reducing the oxygen
Recommendations The authors conclude the technical paper with some recommendations, starting with the fact that TSLs show potential to be used as a gas management tool in underground coal mines. However, there has been limited research into this topic. It is obvious that further investigation is needed in order to ascertain whether this technology can have a significant impact on gas management. Multiple laboratory and field tests under various conditions are recommended. The application procedures for TSLs in gas management in underground coal mines should also be studied and incorporated with the laboratory and field test results. Furthermore, an optimised application procedure of TSLs for gas management should be put forward. “Besides gas management, the application of TSLs can also bring many other benefits, such as in ground support and ventilation. A financial and technical model should be built to evaluate the cost-benefit of using TSLs in the coal mining industry,” conclude the authors.
level in the spontaneous combustion locality. In fact, if applied early enough, TSLs could also prevent the occurrence of spontaneous combustion. The application of TSLs could also potentially reduce the friction resistance of the ventilation airway, thereby reducing power and ventilation costs.
follow the link
To read more go to: www.saimm.co.za/Journal/ v116n12p1091.pdf
In sid e M in in g 0 6 | 2017
35
Company news
Renewing collaboration, improving safety
Mining depends on precision and safety, and now, more than ever, the industry must cut costs while improving safety. Through collaborations, such as the renewed Trysome and Hexagon Mining agreement, mines can integrate, automate, and optimise critical workflows for a competitive edge.
T
Hélio Samora, President, Hexagon Mining (left) with Eddie Smith, CEO, Trysome
sub-regulations that require TMM to ‘fail to safe’ without human intervention by June 2019. The demands of VIS are complex, with varied stakeholder collaboration required – i.e. OEM, mine, manufacturer, distributor and operator groups,”
he renewal of the reseller agree-
“Hexagon’s international experience
ment between Trysome Auto
and Trysome’s 26 years of African market
The mining environment and demand
Electrical South Africa and Hex-
expertise, infrastructure, and footprint are
going forward will be technologically de-
ogon Mining took place recently,
says Smith.
ideally suited for customers facing sec-
manding. Decisions will need to be taken
strengthening the long-standing collabo-
ond-phase legislation,” says Eddie Smith,
quickly and this is where having data at
ration between the organisations.
CEO, Trysome. “With over 150 skilled
your fingertips will allow for fast and ac-
technicians and a team of specialist en-
curate decision-making.
Through Trysome’s footprint, industry relations and technical operational
gineers, Trysome is well geared to meet
experience in the South African mining
local demand.”
sector and Hexagon Mining’s technology
Trysome has represented Hexagon Mining in the sub-Saharan African region since 2008. Today, the flagship CAS is
solutions ethos, which integrates plan-
Supply and support
ning, operations and safety solutions, the
This collaboration ensures continued sup-
hicles in more than 60 mines worldwide.
South African mining sector is well placed
ply and support of the tried and tested,
Samora and Smith agreed that renewed
to meet the demands of the Department
Swiss-manufactured SAFEmine product
collaboration is good news for customers
of Mineral Resources’ recent trackless
suite, which has been actively present
in South Africa.
mobile machinery (TMM) regulations.
and in use in South African mines since
running in more than 25 000 mining ve-
“Deadlines are looming for many mines
2008. It also means strengthened service
Regulations
to comply with South Africa’s new safety
and support for Hexagon Mining’s wider
Since 27 May 2015, all South African mines
regulations, so this is a timely agreement
portfolio of integrated solutions. Besides
are required, by law, to have a Pedestrian
between our companies,” says Hélio
collision avoidance and fatigue monitor-
Detection System fitted to all TMMs.
Samora, president, Hexagon Mining.
ing, these solutions include proven tech-
“Our Collision Avoidance System (CAS)
nologies for surveying, design, fleet man-
of the MHSA Regulations were
and new Vehicle Intervention System
agement, and production optimisation.
promulgated on 27 February 2015. The
The TMM Regulations under Chapter 8
“This dynamic team is already well
regulations came into operation three
people and equipment, as well as meet
advanced with their new VIS solution
months after the date of publication in
those deadlines.”
to satisfy the demands of ‘Phase 2’
the Government Gazette.
(VIS) will help customers protect their
In sid e M in in g 0 6 | 2017
37
MARKET news
market news
from around the continent Dewatering with simple applications
Bell announces black-women-owned empowerment partnership Equipment manufacturer and distributer Bell Equipment has announced the conclusion of a BBBEE agreement with SiBi Capital, an entity entirely owned and managed by black women. Gary Bell, CEO, Bell Group, says the agreement has been specifically structured to pursue real transformation through the economic empowerment of black women, who will add value to the company, while also aligning the company’s business strategy with government’s economic transformation policies. “I believe that this will place Bell in a unique position to be the only yellow equipment company that produces locally. The partnership will allow Bell customers to claim the benefit of purchasing from a 30% black-women-owned entity,” Bells explains.
At the signing ceremony (back from left): Avishkar Goordeen, director: Group Corporate Development, Bell Equipment; Menzi Dumisa, managing director, Bell Equipment Sales South Africa; (front from left) Bharti Harie, SiBi Capital; Gary Bell, CEO, Bell Equipment; and Sindi Mabaso-Koyana, SiBi Capital
SiBi Capital is represented by Bharti Harie and Sindi Mabaso-Koyana, each owning 50% of the entity. “It was necessary to create a sustainable funding structure that is not reliant on external finance. We believe that this objective has been met and that we can create a long-term relationship with SiBi Capital, through Bharti and Sindi, who can add real value to the BESSA (Bell Equipment Sales South Africa) business,” concludes Bell.
Dewatering is one of the most common activities on mining sites across the world. However, it is also one in which the incorrect selection of pumping equipment could have a major negative impact. Lee Vine, managing director, Integrated Pump Rental, cautions that different dewatering applications call for different solutions, and that it is not always a case of one pump fits all. “Most customers need a trouble-free pumping solution, and this means that the pump must be configured for the specific dewatering application,” Vine says. Integrated Pump Rental has built its success on providing fit-for-purpose dewatering solutions to its customer base, and the company operates an extensive fleet of pumps. Included in the rental fleet are the wellknown Grindex submersible drainage and dewatering pumps, the SlurrySucker dredge units, the SlurryBlaster hydro mining equipment solution and Sykes dewatering pumps. The Sykes dewatering pumps have gained rapid traction since being introduced into the Integrated Pump Rental fleet just over a year ago. Vine says that it is the ease with which these pumps operate that has driven the market acceptance. “Sykes pumps are simple to use and can handle high volumes of water with ease. But more importantly, the pumps are available mounted on skids, site trolleys and road trailers. This makes the deployment of this pumping equipment an easy and quick task,” Vine says. There are four different ranges available locally.
LEFT Lee Vine, managing director, Integrated Pump Rental Below Sykes pumps are simple to use and can handle high volumes of water with ease; more importantly, the pumps are also available mounted on skids
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Proximity detection to minimise mine fatalities With a set industry target to eliminate mining fatalities by 2020 and reduce losttime injuries by 20% from January 2017, the pressure is on mines and their suppliers to meet the goal, especially in the field of proximity detection systems (PDS). “Transport-related incidents are still one of the top causes of fatalities, alongside fall-of-ground,” says Anton Lourens, managing director, Booyco Electronics. “While deaths in mining fell 5% to a record low of 73 in 2016 and injuries fell 15% to 2 662 last year, there is still a long way to go meet the 2020 target. PDS allows for interventions where a potentially dangerous situation exists between a pedestrian and a machine. The
system includes a sensing device, to detect the presence of an object in a working area, and an audible and visual alarm to both the equipment operator and pedestrians as they enter danger zones. It can also help locate people and machinery if there is an emergency underground. “The groundwork for the wider application of PDS has already been laid down by the Department of Mineral Resources, through an amendment to Chapter 8 of the Mines Health and Safety Act in February 2015,” says Lourens. “It is now required that PDS be installed on all mobile equipment on mines.” Booyco Electronics Asset Management System (BEAMS) provides underground
ABOVE The Booyco PDS warns when pedestrians enter the area around the machine and has an audible and visual alarm to alert operators if pedestrians enter danger zones RIGHT Anton Lourens, managing director, Booyco Electronics
and surface mining operations with a webbased application and robust database to optimise mine safety and ensure compliance to legislation.
BME adapts mineral scanning for safer blasting In another step towards safer blasting practice, leading explosives company BME is adapting mineral scanning technology to quickly identify reactive ground conditions that could lead to blast site incidents. “We are in the process of advancing and developing our technology by adapting a mineral scanner to identify reactive ground
on the spot,” says Vic Krause, blasting engineer, BME. “This can give us real-time information that eliminates the need for expensive lab tests and avoids having to wait weeks for the results.” He says they are utilising the XRF Delta Pro mineral scanner, which has many mining and geological applications, including mineral identification.
“With this scanner, the user can determine whether the areas surrounding blast holes are reactive,” he explains. “This can be done days before explosives are pumped into the blast holes, so that the correct procedures are followed should reactive ground be discovered in the blasting area.” BME has already developed a specialised emulsion type for use in reactive ground.
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market news
Portable LED light towers shed reliable and efficient light
Lourens Jansen van Rensburg, business development and marketing director, I-CAT Environmental Solutions
I-CAT offers ‘green’ master plan One of the most rigorous and specialised processes for the mining, industrial, manufacturing, and commercial development sectors is environmental licensing and compliance assurance. I-CAT Environmental Solutions offers an Environmental Masterplan to ensure alignment with compliance, auditing and monitoring requirements. “The range of environmental compliance solutions has a specific focus on the mining sector, as prescribed by relevant national legislation and compliance standards,” explains Lourens Jansen van Rensburg, director, I-CAT Environmental Solutions. “The current economic climate in South Africa has resulted in companies cutting down on budget allocation for minimum environmental compliance, yet recognising their obligations to account for their activities impacting on the environment and to accept responsibility for them,” Jansen van Rensburg explains. I-CAT offers an Environmental Masterplan solution through its Environmental Solutions Department that addresses all external environmental licensing, auditing and monitoring requirements. Benefits include cost- and resource-savings, as well as ensuring that all environmental aspects are considered and assessed in an integrated, holistic manner.
Heavy-duty applications in mining rely on reliable and efficient equipment to maintain uptime and keep projects on track to ensure profitability. More sites are operating 24/7, working day and night to meet deadlines and avoid penalties. Atlas Copco Portable Energy has released its latest range of portable HiLight light towers, which incorporate cutting-edge LED technology to deliver reliable and efficient lighting solutions – with up to 25% more light compared to metal halide lamps and average fuel consumptions savings of 60%. “Metal halide lamps can simply no longer compete with the groundbreaking features and cost-saving elements offered by LED technology within the heavy-duty arena,” states David Stanford, business line manager: Portable Energy, Atlas Copco Construction Technique. “In line with Atlas Copco Portable Energy’s forward-thinking philosophy, we endeavour to constantly add value
HiLight LED models decrease maintenance costs by enabling longer service intervals
by anticipating the future needs of our customers and developing products to meet and even exceed these needs. “We recognised early on that LED lighting – driven by extreme durability, superior performance and super efficiency – is no longer a technology of the future but the preferred light source of today and we immediately got to work to incorporate LED technology into our HiLight light towers,” Stanford concludes.
Atlas Copco Portable Energy’s HiLight LED light towers incorporate cutting-edge LED technology
index to advertisers Atlas Copco
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IBC
Komatsu 23
Babcock OFC
Regal Beloit
Bell Equipment
Sandvik Mining
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Dosetech 7
SBS Water Systems
Kal Tire
Schneider Electric
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IFC
SEW-Eurodrive 31
OBC 2
Tenova TAKRAF Africa
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Trysome Auto Electrical
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