www.miningne.ws
af r ic an u pdates on th e
g ro un d a n d un d e rg ro un d
Financial statistics Hopes on the upswing mining in africa Mokopane on the cusp shanta gold Tapping into Tanzania
De Beers
Vibrating screens When bigger is better
Keeping diamond people safe ISSN 1999-8872 • R50.00 (incl. VAT) • Vol. 10 • No. 05 • May 2017
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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
next-generation transformer lubrication 08 Editor’s Comment 3 Charming positivity
12
coal economics 23
Latest status of coal
Cover Story 4 Keeping diamond people safe
Materials Handling 24
Life blood of materials handling
Africa Round-up 7 News from around the continent
25
Conveyor belt efficiency
Shanta Gold 8 Mining gold in Tanzania
Transparency: the next frontier
Chamber of Mines 11 Mining improves financially
Pipes, Pumps & Valves
Mining in Africa 12 Taking safety one step further
Energy efficiency
14
Almost mining tin
16
Another 10 years for Leeuwpan
may
Drilling & blasting 28
30
32
Shell’s GTL-based transformer oils resist degradation in demanding applications, improving transformer uptime.
2017
The importance of valve selection
ON THE COVER p4
Oiling power transformers
Legal 34
Coal processing 18 Bigger is better
Reading between the lines
Market News
Fossil Fuel Foundation 20 Dry beneficiation to upgrade coal
37 The latest news from the African mining industry
16
25
Safety is not an option for De Beers, as people are their biggest assets. Philip Barton, CEO, De Beers discusses how they manage zero harm in the company.
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1
Mathabe Mining Supplies (Pty) Ltd was established in 2010 with the purpose of supplying the mining industry with valuable services and products. Located in the Mabopane industrial area and providing our clients with various process solutions and surface metallurgy expertise. We currently provide products and services nationwide and are always looking to innovate, improve and enhance the mining world of surface metallurgy.
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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 Rosemary Falcon, Henk Langenhoven, Tendani Ndwamise, Selwyn Pearton, Xavier Prévost, Garyn Rapson, Kim Schoepflin, Julien Van Niekerk 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 ___________________________________
W
hat an honour it is to meet some of the big names in the mining industry, and to talk to them about their projects and views of the state of the industry. The names I’m talking about are the CEOs running successful mining houses, and
Inside Mining will be featuring two of them in each edition going forward. Not only are these men charming, but their positive attitudes about the
mining industry are tangible. In this month’s issue, we talk to Philip Barton,
Charming positivity
CEO, De Beers Consolidated Mines, and Toby Bradbury, CEO, Shanta Gold. Both men believe in and apply mechanisation at their mines. They also both agree that people are extremely important in achieving the targets set out, resulting in successful
operations. While the majority of mines today take safety seriously, De Beers went out of their way to cultivate a culture of safety within their people. Barton talks about why and how they have done it, and the results are speaking for itself. Read the article on page 4, or watch the entire interview with Barton at www.miningne.ws/2017/05/03/ new-technology-key-to-solving-mining-challenges-de-beers. To those still wondering whether mining gold in Tanzania is an option, you just need to read the interview with Bradbury on page 8. He is extremely passionate gold and mining in Tanzania. He is also passionate about working in Africa, and developing skills in the African mining industry. For
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him, a big challenge is producing gold at low production costs, and he
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licences where tin used to be mined. There are two deposits in Mokopane
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.
believes that Shanta has achieved this, and is good at it. Then, we also visited Mokopane Tin Project, a brownfields project, situated in the northern limb of the Bushveld Complex. Bushveld Minerals’ approach to tin is to target areas of historic tin production. Therefore, it has secured that will be mined. Read more about this project on page 14. Another project we are looking at in this edition is De Beers’ Voorspoed Mine in Kroonstad. Although De Beers bought the mine in 1912, it only started developments later. Licences were approved and construction was started immediately in 2006, and officially opened in 2008. This mine also shows impeccable safety records, with no loss of life since its inception. De Beers has done extensive work in the communities and thereby earned its social licence to mine. Read more on page 12. Talking about social licence to mine, Exxaro’s Leeuwpan coal mine in Delmas also went out of its way to accommodate the community. It has spent over R25 million on local economic development projects. Currently, the mine is preparing for the construction of its R522 million improvement project that will start Q2 2017. Read more about this exciting project on page 16. As always, don’t forget to read our daily articles on
To our avid readers, be sure to sign up and get the latest updates and inside scoops from the mining industry. Check out what we are talking about on our website and Facebook page, or follow us on Twitter and have your say.
@mining_news
what is happening in the mining industry on www.MiningNe.ws. Don’t forget to subscribe to www.MiningNe.ws for current news about the mining industry.
Mientjie Kleinhans
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In sid e M in in g 0 5 | 2017
3
COVER STORY | De Beers
Keeping diamond people safe A safe working environment is of utmost importance for the company
One of the winders at the Venetia Mine
Safety is a big concern for De Beers, particularly because people are the largest contributors to its recipe for success. Philip Barton, CEO, De Beers Consolidated Mines (DBCM), talks about the company’s excellent safety record, the benefits of mechanisation, and DBCM's future plans.
T
he Company’s recipe for
become even more of a challenge in
Mechanisation
success starts with what it calls
the future,” explains Barton.
Having mechanised years ago,
“diamond people”. De Beers is
He believes that the second
the company is moving beyond
challenge facing mines is water. “We
mechanisation. De Beers in South
of its culture, borne out of originally
know that water is scarce, particularly
Africa, in total, employs only
being a family-led company. People
in South Africa. There is competition
about 5 000 people and began
have long service records at De Beers
for water and it has been highlighted
implementing mechanisation decades
and they bring that extra bit to work
through the recent droughts, and it
ago, notably at the underground
every day.
will increasingly become more of an
operations of Finsch mine. “Our
issue,” says Barton.
current challenge is automation and
all about people, which is part
“Our people are passionate, not just about diamonds, but also about
Drinking water is the number one
autonomous mining. The moment
each other, and they are passionate
priority and after that we need to feed
one moves from mechanisation
about the company. That is why, after
our nation, so agriculture is going to
to automation or to autonomous
129 years, we are still excited and still
get the second bite, and mining that
mining, everybody wants to know
successful,” claims Barton.
uses a lot of water is going to be last in
about jobs.
the queue for the available resources.
Challenges
“We only employ people with
“Both lack of skills and water shortages
matric and beyond, and we’ve seen
“We face a number of challenges as
need to be solved and we are looking
the benefits of lifting that skills level.
a miner in the industry. One issue that
to do this through technology. As we
People are coming in with high skills
is not unique to South Africa is the skills
introduce technology, innovation,
and are able to progress much better
that we attract to this industry. In short,
and new thinking, it will bring more
in the company. The benefit for us
mining is not that sexy anymore and
excitement back into the mining
is that people are better educated,
people don’t realise the significance
industry. It will attract people and bring
and understand a lot quicker. The
that mining plays in our everyday lives,
the right skills to the mining industry,”
challenge for us is not to reduce
locally or internationally. Less and less
says Barton
jobs, but to have more exciting jobs
people actually choose mining as a
He adds that mines need to look not
with better skills and better salaries
career. To attract the right people and
only at how to use less water, but the
that come with automation and
the right skills into the mining industry
ultimate goal is how to mine without
autonomous mining,” says Barton.
is already a challenge, and we believe this is going to
water. “Especially on our recovery side, it is a real challenge, but we have been working on that for a few years now with some success. Technology and innovation must
Entrance to the Venetia Underground Project
Projects Two of the operating mines in the De Beers portfolio are Venetia and Voorspoed. Both these mines are operating and producing at full
be the solution that
capacity. Both mines are getting to
we are looking to
the end of their economic open-pit
in the future.”
lives and Venetia is being converted
An overview of the Venetia Underground Project
In sid e M in in g 0 5 | 2017
5
COVER STORY | De Beers The MV SS Nujoma
loved one, or even an important event. “They want to be there, and they want to provide for their families. They made a personal commitment to be safe at work, because they have to go home to their families every night. “We then followed up with who the safety leaders among us are and we realised that every one of us is a safety leader. We came up with the criteria of
De Beers projects South Africa • Jwaneng • Voorspoed • Venetia
Namibia • MV SS Nujoma
a good safety leader and people are
In Canada • Gahcho Kué – the largest new diamond mine under development in the world
now aspiring to meet those criteria,” says Barton. The next step was to identify the safety controls to protect people and ensure that everybody understands them. “This year, we have realised
The Venetia Mine Underground Project
that the system, at some stage, has become complex, so our key focus now is on simplifying it. Ultimately, it is about taking accountability for my safety and to look out for my colleagues,” says Barton. He adds that the controls are also being introduced into production. “I am accountable for my job. There are no excuses. That is the part that I have to produce, but I am also part of a team, so I contribute to the team and
Mining is not that sexy anymore and people don’t realise the significance that mining plays in our everyday lives.” Philip Barton, CEO, De Beers Consolidated Mines
help the team to succeed. “Within the areas of safety and production, everybody takes accountability for themselves and as part of a team, with no excuses. We believe we will have safe production, and that zero harm at the end of the
to an underground mine. Barton
Safety
adds that one of the other projects,
The company is 129 years old. During
Zero harm
Jwaneng, is one of the deepest open-
this period, besides the World Wars and
“I fundamentally believe in zero harm
pit mines being created, and is
the Great Depression years when all
and so do the people at De Beers
doing exceptionally well.
diamond mines suspended operations,
and Anglo American, our owners. It
“Closest to our heart is the
2016 was the best year ever in terms of
is something that we have proven is
Venetia underground project.
safety for DBCM. “We are unbelievably
possible. We haven’t had a fatality in
It is a 10-year project where we
proud of that. We’ve had no loss-time
De Beers since 2008 in South Africa”
are spending over US$2 billion.
injuries on our operating mines, and on
says Barton.
Anybody who doubted De Beers and
the usually challenging shaft sinking
Anglo American’s commitment to
side, our decline development has
than two years without loss-time injury,
South Africa just has to look north
now been three years injury-free.
and the last loss-time injury at Venetia
and see what we are doing there.
“We believe that safety is an ongoing
Voorspoed Mine has gone more
mine was in July 2015. Voorspoed Mine
For us, that is the most exciting
journey. At De Beers, it is not production
hasn’t even had any minor injuries
project for the main reason that it
safety, it is safe production. Safety is
in the last year that required any
is in South Africa and in terms of its
our number one priority; it is part of our
medical treatment.
diamond recovery technology,”
core values. We have embarked upon
says Barton.
a journey, we’ve made it personal – it
harm is possible, then nothing is.
is a passion about people that is almost
We believe fundamentally that it is
tangible,” says Barton.
possible and that if we work at our
In Namibia, the company has an exciting project with a new exploration and survey vessel, the SA
6
day is achievable,” says Barton.
The company asked its people a
“If this isn’t proof enough that zero
behaviour, taking responsibility for
Nujoma, which has been successful,
couple of years ago why they want to
our behaviour and actions, then
ahead of schedule, below cost, and is
be safe. The overall reason for people
we will indeed achieve zero harm,”
busy with its sea trials.
to be safe is to be there for a child, a
concludes Barton.
Ins i de Mi n i n g 0 5 | 2 0 1 7
Mining news
from around the continent
Ethiopia
Ethiopia exerts effort to leverage mining industry
solid minerals sector of the economy off the ground are yet to be activated. The Minister of Solid
Private companies in Ethiopia are ac-
Minerals Develop-
tively engaged in almost 99% of the min-
ment, Dr Kayode
ing industry, said the Ministry of Mines,
Fayemi, gave a
Natural Gas and Petroleum.
worrisome comment
State Minister Tewodros Gebre Eg-
on the strategic initi-
ziabher told the Ethiopian Herald that,
atives of the ministry,
previously, mining activities have been
though the country is abundantly
carried out by the government, but now
blessed with so much of solid minerals.
private companies have become domi-
He told the audience at a
South Africa
Ransacked gold mine to be resuscitated South African mining veteran Peter Skeat is pressing ahead with plans to squeeze more gold out of an 80-year-old ransacked gold mine west of Johannesburg after settling a dispute with three former partners. The entrepreneur, who is part-financ-
stakeholders meeting held in the
ing the venture himself, is seeking
Benue State that government could
investors to help fund a revised de-
has already shown progress in terms of
ban the importation of certain
velopment plan at the Blyvooruitzicht
its contribution to the national economy.
minerals it considers a high priority.
Mine after receiving a 30-year mining
These minerals are limestone, barites,
right for the operation on 6 April.
nant in the industry. He emphasised that the mining industry
Mining in Ethiopia makes a great contribution to the national economy
iron, bitumen, lead and zinc. He
$100 million rebuilding Blyvooruitzicht,
would help stimulate the local mining
which was overrun by illegal miners
industry. Nigeria's solid minerals
and its equipment looted after it was
industry has not been developed
abandoned by the previous owners
to a level competitive enough to
in 2013.
make a ban effective. The ministry
mined and the country has been earn-
Blyvooruitzicht “has been through
believes this should be addressed by
some hard times, but we’re confident
the government.
in our plan to get it producing at
The ministry needs to be more stra-
He said, "Gold has been extensively
Skeat plans to spend approximately
hoped that the ban, if implemented,
the lowest cost for any underground
tegic in identifying the sector's prob-
mine” in South Africa, Skeat says. The
lems and designing the solution to fit
support structures contain relatively
the uniqueness of Nigeria's environment
high-grade ore and can be mined
and society.
because they’re redundant, he adds.
Meanwhile, the Raw Materials Re-
At an average of about 13 grams
ing a great deal of hard currency over
search and Development Council
per tonne of gold, about three times
the last 15 years. The same is true for
is counting hundreds of mineral de-
higher than a typical South African
opal and other precious minerals.
posits. A proper identification of the
gold mine, Skeat says he can produce
nation's natural endowments needs to
some 100 000 oz a year from the pil-
ing on developing the country's enor-
be done to guide the government in
lars at all-in-sustaining costs of $600
mous potash and iron ore fit potentials
determining informed priorities.
an ounce.
“Right now, the government is focus-
with a view to produce locally made fertiliser and steel.” The companies that were inactive for a long time after being issued with mining licences were stripped of the licences and have been replaced by vibrant mining companies that have good reputations and capacities, he added. According to the minister, incentives packages for the mining sector in Ethiopia are comparatively better than other African nations.
Nigeria
Activating the solid minerals sector There are indications that the efforts of the Nigerian government to get the
Some 27 million ounces of gold resources are yet to be extracted in the abandoned Blyvooruitzicht Mine
Shanta Gold
Mining gold in Tanzania
An aerial view of New Luika Gold Mine
Exploring and mining the underutilised areas of Tanzania is Shanta Gold, with its prime project being New Luika Gold Mine. CEO Toby Bradbury shares his recipe for success and views on gold mining in the East African country. By Mientjie Kleinhans
T
where else. “I see Africa as an attractive destination for people to want to work in. The continent is crying out for opportunities to grow, so there is generally a supportive environment for investment in Africa,” says Bradbury. He adds that there can be some challenges associated with the
he recipe to success is quite
smart ways of getting the maximum
understanding of the mining industry. The
complicated, according to Brad-
value out of the New Luika resource and
chambers of mines in the various coun-
bury. For him, the primary concern
then continually seeks to improve on
tries have to work hard to ensure a good
is to recognise that mining a min-
it. And that is part of the culture, vision
understanding of the very high capital
and values that we have created in the
investment requirement that goes with
company,” adds Bradbury.
mining, and the long-term payback that
eral resource can only be done once. “It needs to be mined in the best
possible way. You don’t get a second
He says it is part of what the company
is required for shareholders to get their
chance to come back and do it again
does and adds that having good peo-
if you get it wrong the first time. Our
ple improves the recipe for success, as
philosophy is to make sure that we
well as a very strong belief in what can
Gold mining
build in as much innovation and quality
be achieved, even when the odds seem
Bradbury believes that gold is different
into our plan right from the start, and
to be pretty stacked against them.
to the other commodities, in the sense
then implement that plan as we pro-
investments back.
that it is not a supply-and-demand-
gress and develop. We continuously
Challenges
check on our performance and, at the
“When it comes to challenges, I would
“There is some consumption in terms
same time, look at ways to improve on
say Africa is not unique. The mining in-
of jewellery, but, in large, it is more for
the plan that we have put together,”
dustry is very much a global one and
investment. Therefore, one doesn’t need
explains Bradbury.
the competitive environment in which
to mine gold in order to buy it. There is
we work – both in terms of capital and
stock in vaults all around the world, so
competition for skills – is one that affects
the supply and demand link is just not
“Looking at Shanta’s performance over the last two years, our approach reveals
8
Africa just as much as it affects any-
Ins i de Mi n i n g 0 5 | 2 0 1 7
driven product, but an investment metal.
BUSHVELD Shanta MINERALS Gold
The processing plant at New Luika Gold Mine
there in the same way, and that is what
level of technology of the equipment
Gold Mine – and the other project is
makes gold a little more challenging.”
that we use is seriously advanced,”
Singida, a development project. They
says Bradbury.
are in different parts of the country:
He adds that what becomes really important from a producer’s perspective
Although there are certain areas that
New Luika is in the south west and Singi-
is that, to the extent that supply and
are already automated in mines, like in
demand does flare apart, it is important
processing plants, Bradbury doesn’t feel
to be a low-cost producer. “And that is
that autonomous mining is the answer.
ject, according to Bradbury, as it is
common in any commodity, but it is par-
“Mining is an enormous social contributor
already generating cash and it is a low-
ticularly important in gold. For example,
and part of that contribution is in actu-
cost operation. “Last year,
if gold sells for US$500 an ounce and you
ally providing employment. The cost of
we produced 88 000 oz
can’t produce gold at US$500 an ounce,
employment is, in global terms, still very
of gold and we just an-
then you will go out of business. While this
low, so it doesn’t make sense to spend
nounced our mine busi-
is true for every commodity, there are
capital on replacing jobs when that is
ness plan for the next
still sources that will supply gold, not from
the case. A country like Australia has
seven years for New Lui-
mines but from vaults. This is what sets
been different for a very long time. For
ka to the market. It has a
gold apart. We are comforted by the
20 years, the Australian mining industry
huge upside in terms of
fact that we produce at low cost, which
would invest US$1 million to get rid of one
additional resources that
gives us a margin of comfort in terms of
job. You wouldn’t do that in Africa,” ex-
are not yet included in the
volatile gold,” explains Bradbury.
plains Bradbury.
mine plan.”
Mechanisation
Projects
to be a long-life
“I definitely believe mechanisation will
Shanta Gold has two projects in its
operation – it is
work in Africa. Our own mine, New Luika,
portfolio, both in Tanzania. One is an
low cost, high
is as mechanised as you possibly get in a
operating gold mine – the New Luika
grade and an
da is the central part of Tanzania. New Luika is the most exciting pro-
The project is intended
global sense. We are using all the modern technologies available in the market, and it is working very well. We are in the development phase at the moment and just moving into production, but the
“Our philosophy is making sure that we build in as much innovation and quality into our plan right from the start.” Toby Bradbury, CEO, Shanta Gold In sid e M in in g 0 5 | 2017
9
Shanta Gold
The entrance to the underground gold mine
“Mining a mineral resource can only be done once.”
exciting cash generator for the company.
have strong capabilities in terms of pro-
oping project. We are
jects execution and delivery and those
using some of our cash
are valuable attributes that we can
to do exploration work,
use to build our business from here,”
which will then lead to
potentially become a mine in the
Future plans The company plans to continue with its
Gold from an 80 000 to 90 000 ounce per
brownfield exploration at the New Luika
year producer to a potentially 120 000 to
mine, which will progressively continue
130 000 ounces per year producer.
to add life to an existing asset. From a shareholder point of view, the invest-
want to produce gold simply to produce
ment that has been made in the mine
gold, we want to produce gold at a low
got the opportunity to provide returns for
cost. That is what we are focused on
the long term.
and very good at, but we also recognise
“We are using our skills base and ca-
that in order to get the attention of the
pabilities to grow the business outside of
investment market, we need to have a
our existing portfolio and that could be
certain level of scale,” says Bradbury.
outside of Tanzania as well. We are not
He adds that growth is an important
necessarily fixed on operating in Tanza-
part of the company’s programme. It is
nia; it could be elsewhere in Africa, or
also looking at both of the internal pro-
elsewhere in the world, but I think Afri-
jects, and other opportunities that will
ca is a very comfortable destination for
bring skills and capabilities to the benefit
the work that we do,” says Bradbury.
of other projects that may be underper-
“Shanta Gold is a gold company,
forming, or potentially near develop-
and we believe that investors invest in
ment projects that are close to getting
us because we are a gold-producing
into production.
company. I’m not saying that I wouldn’t
“Over the past 18 months, we have
Ins i de Mi n i n g 0 5 4 | 2017
boasts Bradbury.
next two years. That would take Shanta
“That is important for us, not that we
10
to plan in terms of time and cost. We
“Singida is a devel-
feasibility studies for Singida to
Shanta Gold will continue to focus on gold
all of that work has gone according
be interested in supporting other
built a 7.5 MW power station and a
commodities, I think the base metals
dam on the Luika River that will provide
have a huge upside from where we
water security; we are completing a
are right now. However, we think that
tailings storage facility; and we are
focusing on gold is the best plan of
developing an underground mine. And
action,” concludes Bradbury.
Chamber of Mines
Mining improves financially production is still 15% below the 2005 peak, and seems to be moving in a
The hopes of the mining industry are on the rise, owing to the latest financial stats from Stats SA. These confirmed a tentative improvement financially in the mining industry during 2016, keeping in mind that 2015 was a year with low commodity prices and huge performance swings. By Henk Langenhoven*
T
band of 10% to 15% below the peak level. Over the last 12 months, production declined by 4.5% (as at January 2017). There is some hope though; January 2017 production was nearly 2% better than December 2016 and over 2% better than during January last year. These short-term improvements will have to continue for the trend to turn positive. The next indicator to monitor would be employment numbers. Both employ-
he sector’s profits before taxes
indicators, it is worthwhile to restate
ment numbers and gross fixed capital
improved by R19.6 billion (2013 to
their patterns.
formation spending indicate whether
2014), declined by R68 billion (2014
World economic growth seems to be
companies have more confidence in
to 2015) and improved again, ac-
recovering, albeit slowly and varied in
future prospects. According to Statistics
cording to the latest data, by R72.2 billion
different markets for mining commodi-
SA and the SA Reserve Bank, mining
(2015 to 2016). This brings the
fixed investment de-
sector virtually on par with its
clined in 2016 by 3.7%
position in 2014.
on 2015, which is not
Since 2012, the pattern of
good news. However,
stagnant profitability seems
the release by Statis-
to have established. For the
tics SA shows that the
last eight years, during every
fourth quarter capital
quarter since the middle of
expenditure was al-
2012, barring the last quarter
most on par with a
of 2016, mining sector profits
year ago, and may
before taxes were below the
indicate that a lower
average. The trend line seems
turning point has been
to be improving though.
reached.
While this trend is encour-
If one imagines
aging, it will have to continue
‘waves’ or leading
for the sector to regain its growth potential. It seems to have been the result
graph 1 Net profit and loss before taxes (R16 billion average)
indicator ‘cycles’ for the mining sector, then the clarification above shows
of positive leading indicator trends (as
ties. Commodity prices, in general, seem
where signs of improvement are visible,
discussed below) as well as massive
to have gone past the bottom of their
and which ones to next watch out for
adjustments within the mining sector to
cycles and clearly had an impact on
that will invoke more confidence in re-
ensure survival.
company performances, due to the
covery in the mining sector in months
‘windfall’ effect of better prices.
to come.
Indicators
The next indicator that should respond
Despite uncertainties regarding the
is mining production; but it has not im-
*Henk Langenhoven is the chief
direction of every one of the leading
proved in any significant way. Mining
economist of the Chamber of Mines.
In sid e M in in g 0 5 | 2017
11
mining in africa
Taking safety one step further Although the Voorspoed Diamond Mine near Kroonstad is fast approaching its end of life, owner De Beers is looking for ways to economically lengthen its lifespan by a year or two; all the while, management is taking safety one step further.
People are important to the mine, and De Beers encourages safety on every level of people’s lives
ne of the ways that De
O
weekend addressing transport acci-
Beers promotes safety in its
dents and the need to properly plan a
mines is through focus en-
route in advance, whether it is for work
gagement sessions, where
or going on holiday. “By expanding the
small groups of workers are educated
focus even outside the mine, we ensure
on certain aspects of safety. These safe-
that when the people leave the mine
ty talks not only address areas within the
they still think about safety and travel
mine, but also address issues within the
more safely. The sessions explain to the
private lives of people.
groups why accidents happen, and
“By cultivating a safety culture in all as-
how to plan their trips,” says Xulu.
pects of people’s live, safety becomes
“Most people just get into a car and
second nature, and people won’t even
go on a long-distance trip and just take
have to think about doing things safely,”
everything for granted without checking
says Luyanda Xulu, senior engineering
the tyres or giving the car an overall
manager, Voorspoed Mine.
inspection. They don’t plan the trip in
One such example is a focus engagement session held just before the Easter
terms how far to drive before filling up on fuel, how many people are travelling, what the estimated time of arrival is, or weather conditions,” says Xulu. He adds that the focus groups
Safety is a big concern at Voorspoed and has proved that zero harm is possible
12
Ins i de Mi n i n g 0 5 | 2 0 1 7
Voorspoed Mine is an open-pit mine with four years life of mine left
are small – between 10 to 14 employees. “If people strongly believe in what they do, they will do it without having second thoughts about it. If it is an instruction, or a procedure, then people do it to comply, but they don’t necessarily believe in it. We try to have a work culture where people not only willingly comply unconsciously, but believe in what they have to do,” explains Xulu.
Safety record Both De Beers Consolidated Mines and Voorspoed Mine can prove that their safety initiatives pay off, as Voorspoed Mine alone has been operating for two
Voorspoed Mine facts • Open-pit mine • Kimberlite resources
4 years
0.3 M₵
0.2 Mt
15.4 cpht
Remaining life of mine
Saleable carats
Treated tonnes
Recovered grade
years without any injury. “We believe that 2016 demonstrated that zero harm
“This year, we have been badly affected
Diamond sorting
is achievable in the sense that, by the
by abnormal rainfall. With so much rain,
The mine continuously looks for innovative
end of 2016, we had had two years with-
the pit becomes inaccessible as the
ways to sort diamonds, and many of the
out any of our employees getting hurt on
trucks can’t operate in those conditions.
ideas originate from the teams. It has re-
the mine. Not one of our employees lost
Although we were able to still reach
cently done a number of upgrades with
a shift due to an occupational injury on
our mining target, we could have done
the sorters and recovery where it has in-
the mine,” says Xulu.
much more if it wasn’t for the rainfall.
troduced new technology. “We are plan-
Where we had budgeted for nine days
ning to introduce an X-ray transmission
of rainfall, we ended up with 22 days in
(XRT) machine during the course of this
From a production perspective, the
the first quarter of the year. As a result,
year. This will also ensure that the process
total tonnage mined in 2016 was above
our current production is slightly lower,”
is efficient and effective in the recovery
the budget by almost 900 000. Howev-
explains Xulu.
area. That will also help us to make sure
Production
er, the end product is currently down.
He adds that the mine is hoping for a
that we process quicker and more effec-
In 2016, production managed 649 000 t,
dry winter period where it will be able
tively as the machine can sort diamonds
while in 2015, 704 000 t were produced.
to produce unencumbered by rainfall.
faster and more accurately,” says Xulu.
That means production was down
What it has done for the Q2 budget and
by 8%.
going forward, is to change its focus in
Future plans
terms of the rainfall, and it has done a
He says that currently the mine doesn’t
683 000 and we ended up just shy of
lot of work on the roads. “Rain damage
have a long life of mine, so the future
650 000 for the current year. The reason
causes potholes for instance, and it hap-
plans currently are to keep the mine
for the decrease is that we mine the in-
pens in the pit as well. Therefore, we use
running at a steady rate. There are no
ferred resource and we had to deal with
reconstructive construction to be able
plans to open another cut yet, and while
a lot of geological challenges of unex-
to access the pit in the aftermath of the
a number of studies have been under-
pected grain changes.
rain much more quickly than normal,”
taken, there are no new plans on the
says Xulu.
cards yet. The life of mine is until the end
“We were supposed to produce
of 2020.
In sid e M in in g 0 5 | 2017
13
mining in africa
Almost mining tin The Mokopane Tin Project on the Northern Limb of the Bushveld Complex is scheduled to commence production before the end of 2017, pending the granting of the mining licence. In the interim, the team is preparing geological, mining and metallurgical plans in ancipation of the restart of mining operations, which have been dormant for some 30 years. By Mientjie Kleinhans
B
ushveld Minerals’ Mokopane Tin Project consists of three mineralised areas that will be mined for tin once mining authorisation has been granted. Two of these areas will be exploited by open-pit
operations – the Zaaiplaats open pit and Groenfontein open pit – while the third area, the old Lease Workings, will resume the mining of an old underground mine which is being re-evaluated. The Zaaiplaats open-pit project forms part of an abandoned mine comprising an open-pit underground section while the mineralisation at Groenfontein was only sporadically worked in the past, mainly from surface. “We have looked at all the old mining and exploration results and identified the Groenfontein area where an outcropping body of disseminated tin, although lower in grade than the high-grade pipes mined in the past, contains a higher-grade central core which is amenable to economic exploitation at current tin prices and low-cost open-pit mining says Professor Richard Viljoen, technical advisor to Bushveld Minerals. The old Zaaiplaats open-pit and underground mine was the second largest tin producer in South Africa for many years. The previous owners mined mainly high-grade pipes of tin in the granite, but stopped in the 1990s when tin prices came crashing down. Bushveld’s exploration programme has established a resource of open-castable tin that can be accessed from the old pit. “Mining is planned to start in the Groenfontein area where we have a resource of some 5 000 t of tin. This will be followed by mining in the old Zaaiplaats open pit where our
mining in africa
exploration programme has defined a
been one of the best performing metals
thick with a rich core of dissemination,”
resource of some 5 Mt of disseminated
on the London Stock exchange and we
explains Richard.
tin. We will the concentrate on the shal-
see a gap in the market. Tin is an impor-
low underground mine at the old lease
tant commodity worldwide but has been
Business model
workings where a resource of 5 000 t of
somewhat neglected on the capital
The business model that the company
somewhat higher-grade tin is anticipat-
markets and we want to capitalise on
wants to follow is to look for additional
ed to occur,” explains Richard.
that,” says Anthony.
zones of disseminated tin of somewhat
There are at least two additional tar-
lower grade, but on or near the surface
gets besides the obvious three areas
One of a kind
where mining will commence, within the
Anthony says that what makes the pro-
tive to mine. “It is a shift in doing business
Mokopane Project area. “Our strategy is
ject unique is that much of the Moko-
and if we encounter unmined pipes con-
to mine the first three areas while simulta-
pane resource is open-castable, it is
taining tin, it will obviously be a bonus,”
neously exploring the adjacent areas, as
situated in a good mining jurisdiction and
says Richard.
and that are easier and more cost-effec-
“We will start off on a relatively mod-
well,” says Richard.
est scale with a 20 t/h gravity sepa-
Timelines
ration plant. Our target is initially to
“The main issue at present in-
produce 10 t of tin concentrate in a
volves outstanding permitting
month and ramp up to 40 t a month
with the Department of Min-
and then 60 t of tin a month. The pro-
eral Resources. We have
ject has a relatively short 10-year
the mineral rights and they
life of mine on three of the five
are due for renewal, but it
targets. We want to extend
just takes time to get them
this to a 20-year life of mine,
granted,” says Anthony Vil-
because of the several
joen, non-executive director,
interesting targets where exploration will contin-
Bushveld Minerals. “We are looking to mine in a more cost-effective manner namely smaller deposits with higher grades, a short mine life, offering cheaper, preferably open-cast mining, and simpler plants”. We intend beginning at Groenfontein with a mobile
tin is a metal that
plant,” says Richard.
has unique metallur-
He adds that their aim is to establish a
gical qualities. “Since
“Our strategy is to mine the three areas and then explore the other target areas close by as well.”
critical mass of tin with an eventual total
these mines closed
target of about 50 000 t of contained
in the 1990s, no one has
tin in a resource. “We have looked at
made an effort, up until now, to
a number of different deposits, and
resuscitate them.”
50 000 t of contained tin is roughly the
“Another important aspect is that the
ue while we are mining,” says Anthony. In addition, the underground mine at the Lease Workings is still very much intact. “It is a solid area with a
competent Granite shell, reducing the incidence of rock falls, and what we want to do is to resume from where the old owners
minimum benchmark of junior tin miners
‘old timers’ at Zaaiplaats were spoiled
left off. The previous miners stopped
around the world at present.”
by the high-grade tin in the pipes they
mining about 30 years ago and the
mined until they encountered low-
underground workings are in near-
is to establish Greenhills Resources, cur-
er-grade disseminated material. The
perfect conditions. We will study the
rently a part of Bushveld Minerals, as
blanket of disseminated tin at Groen-
rock formations to make sure that it is
an exclusively tin-focused entity. Tin has
fontein, for example, is about 15 m
safe,” concludes Anthony.
“What we want to do in the long term
In sid e M in in g 0 5 | 2017
15
Coal mining
Another 10 years
for Leeuwpan
Leeuwpan Coal Mine in Delmas, Mpumalanga, has managed to extend the life of mine for another 10 years with the LIFEX optimisation project. The implementation of the R522 million improvement project is intended to commence during the second quarter of 2017.
E
and shovel operations in the conven-
tional open-pit mine. The current operations for the overburden removal have been outsourced to a contractor who will mine 28 Mtpa, which will increase to 43 Mt in 2020. “We will mine Seam 2 and Seam 4. There is also Seam 5, but it is not economical for us to mine it, as it is low-quality coal. Seam 4 consists of 4 Upper and 4 Lower with different coal qualities. While 4 Upper material will be sent to the dense-medium separation (DMS) plant,
xxaro’s plans for optimising
just waiting for two authorisations for
4 Lower material will be sent to the crush
the project will increase the life
the road diversions of the R50 and the
and stack plant,” explains Sethethi. He
of mine from 2017 to 2027, and
road leading to Thaba Chueu Mining,”
adds that Seam 2 also consists of an up-
the company will continuously
says Sethethi.
per and lower seam, and that 2 Upper is
explore additional reserves around the
Once in full operation, the mine will
Victor Khanye Local Municipality to in-
supply saleable thermal and metal-
crease its life of mine beyond 2027.
lurgical coal to domestic and export
“The current reserves have the po-
markets. The proposed new open-pit
tential to increase the life of mine
mine will result in mine production
to 2030, but there are other areas
of 4 Mtpa from a ROM of 7 Mt.
high-quality coal that will be sent to the second DMS plant.
Processing plants Leeuwpan has its own DMS plant, which mainly beneficiates the metallurgical
that we are trying to acquire to
It contains measured mineral
and export coal, and a crush and stack
take us beyond 2030,” says Man-
resources of 54.8 Mt.
plant, which handles selectively mined
galiso Sethethi, business unit manager, Leeuwpan Coal Mine. The current mining rights will lapse in 2040.
The mine will make use of modified terrace configurations, and truck
power station coal. The third processing plant is another DMS plant that replaced the jig plant in December 2016 and ramp-up production from this plant
The construction of the box-cut is expected to begin in the second half of 2017, and the first coal from the new pit is expected in Q1 2018. “We are
16
Insi de Mi ni ng 0 5 | 2 0 1 7
During 2016, we mined a total of 6.42 Mt ROM and sold a total of 3.77 Mt product.” Mangaliso Sethethi, business unit manager, Leeuwpan Coal Mine
Coal mining
recently started. This DMS plant will be
although road transport is also catered
approved Leeuwpan LIFEX bankable
operated and maintained by a con-
for,” says Sethethi.
feasibility study include the following:
tractor and the product produced from
• Relocation of the R50 road
this plant will mainly be routed into the
Feasibility study
export market.
He adds that the focus for 2016 was to
• Relocation of the Rietkuil community
conclude the Leeuwpan LIFEX banka-
• Wetland offset study.
ity of 470 tph, while the contractor’s plant
ble feasibility study for Leeuwpan. “This
“The mine has been involved extensively
has a capacity of 350 tph. “The new DMS
study was completed during the year
with local community development
plant that is contracted out is doing ex-
and the outcome was presented to Exx-
in different aspects, including a TVET
tremely well. The product produced from
aro Resources during September 2016.
college and bursary programmes. This
this plant will be mainly routed for the
Management of Exxaro Resources then
project is anticipated to create more
export market,” says Sethethi.
approved the bankable feasibility study,
than 200 temporary jobs around the
subject to the suspensive conditions re-
Delmas area, which will contribute
to another contractor and has a capac-
lating to receiving the final environmen-
positively to the economy of the area.
ity of 300 tph.
tal approvals for the R50 road relocation.
Currently, we employ 640 people,
They found the project to be technically
excluding contract workers.
The Leeuwpan DMS plant has a capac-
The crush and stack plant is outsourced
“During 2016, we mined a total of
• OI reserve box-cut
The contractor workforce is
6.42 Mt ROM and sold a total of 3.77 Mt
feasible and it will form a substantial part
product. The mine is equipped with a
of the remaining life of mine for Leeuw-
1 700 people, and that includes
rapid-rail load-out station and this is also
pan Coal Mine,” says Sethethi.
the temporary workforce that is
our preferred means of coal off-take,
The main items linked
some History
Leeuwpan Leeuwpan Coal Coal Mine Mine isislocated locatedin inDelmas, Delmas, alongside alongsidethe theR50 R50 secondary secondaryroad. road.The Themine mine is is serviced serviced byby aa rail rail track, track, which which includes includes a rapida rapidrailrail load-out load-out station station forfor loading loading trains. trains.
to the outcome of the
Iscor Iscor LTD LTD bought bought the the Leeuwpan LeeuwpanCoal CoalReserve Reserve from fromaacompany companynamed named Southern SouthernSphere Sphereinin1988. 1988. Exploration Exploration continued continued year year onon year year over over the the whole whole project project area, area, systematically systematically increasing increasing geological geological confidence confidence andand defining defining coalcoal reserve reserve blocks blocks in more in more detail. detail.
used during major maintenance,” concludes Sethethi.
The majority of the resources at Leeuwpan are currently at 100 m x 100 m drill spacing dependent on infrastructure and wetland restrictions. Areas with high geological variability have a smaller drilling grid size to increase the confidence level of the various resources.
Kumba’s Kumba’s exploration exploration startedin in1990, 1990,which which started ledtotothe theopening openingofof led box-cutfor formining mining a abox-cut 1992.Mineral Mineral rights inin 1992. rights Leeuwpan were toto Leeuwpan were originally owned originally owned by by Kumba Coal Kumba Coal Pty(Pty) Ltd, Ltd, which a 100% which waswas a 100% owned owned company subsidiaryof subsidiary company of Kumba Kumba Resources Limited. Limited. AfterResources the unbundling After Resources the unbundling of Kumba in Kumba Resources 2006,of the mineral rights 2006, mineral were in ceded tothe Exxaro rights were ceded to Resources Exxaro Resources.
coal processing
Recently manufactured large vibrating screen destined for a coal mine in Mpumalanga
Bigger Financial pressure on coal mines in recent years has encouraged the trend in coal processing towards larger screening equipment to achieve higher throughput and efficiencies. The challenge is to ensure good engineering so that bigger is, in fact, better. By Kim Schoepflin*
For example, pipes or circular hollow sections – rather than the traditional H-beams – are used as cross-members, as these are the main structural elements holding the side plates of the screen
C
together, as well oal remains the back-
size distribution and
bone of the world energy
cut size.
system, providing more than a quarter of global elec-
vibrating screens of
tricity generation. As South Africa works
these dimensions –
to extend access to electricity to 95%
from various suppliers
of the country’s households, coal will
– operating in the local
still account for about 80% of Eskom’s
coal processing sector,
output by 2020. To keep electricity af-
and many of them are
fordable, however, coal processing effi-
approaching that point in
ciencies must continually be raised and
their life cycle where they will
costs must be contained throughout the
need to be replaced.
supply chain. Our company works closely with coal
Banana screens
as supporting the screening deck. Circular hollow sections provide greater torsional stability, which is especially important on
these large vibrating screens, and they allow for a more even distribution of stresses. H-beams are more prone to bulk
mines to manage screening costs as an
The 4.3 m wide banana screens cater
failures as the stiffness around the end-
important aspect of their coal process-
for this need and incorporate the latest
plate is not evenly distributed. Circular
ing functions. We already have many
technology. To make sure that a larger
hollow sections are also easier to pro-
screening and feeding installations suc-
screen is going to deliver better results
tect with rubber lining, ensuring optimal
cessfully operating across South Africa’s
and lower costs of ownership, both the
life of these high-wear components.
coalfields – providing lower operating
design and the engineering need to
The pipe cross members are rub-
costs per tonne through high perfor-
be of a high standard. A screen may
ber-lined so that they can be simply
mance and longer machine life.
be sufficiently strong to manage the
rotated – rather than replaced – when
throughput, for instance, but can still
the lining on one side deteriorates. The
our large 4.3 m wide vibrating screens,
wear at certain points – leading to dis-
structure of the pipe itself remains intact
which can handle up to 1 200 tph – de-
ruptive early maintenance interventions
and protected, and the wear life of the
pending on the application, particle
and costly downtime.
pipe is thus extended substantially.
One of the ways we do this is through
18
There are about 60
H-beams are more prone to bulk failures, as the stiffness around the end-plate is not evenly distributed
Ins i de Mi n i n g 0 5 | 2 0 1 7
coal processing Galvanised exciter-driven single-deck drain and rinse screen for a coal application
Kwatani service on-site inspection of exciter-driven feed preparation screens
Multilayer linings
components do not need to be taken
of vibrating screens in
To indicate the level of wear on the
out of the screen to be checked.
the field, and feeding
pipe’s rubber lining, we also offer mul-
A vital advantage of technical know-
tilayer linings of different colours. Cus-
how is the application of in-house finite
quent screen designs,
tomers can then fine tune their main-
element analysis (FEA) capability, to
constantly enhances
tenance programmes by monitoring
finely adjust vibrating screen designs for
the focus on reduced
wear according to which colours are
optimal performance and longevity.
downtime and ease
exposed by wear.
Many screen manufacturers have to
of maintenance.
This not only means a longer
this data into our subse-
outsource this function, adding signifi-
lifespan for all the components involved,
cantly to the overall cost.
*Kim Schoepflin is the
but there is the added advantage that
Continuously assessing failure modes
CEO of Kwatani.
Dedicated to Brilliant Service
PART OF THE MINING PROCESS
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Fossil Fuel Foundation
Dry beneficiation to upgrade coal The paucity of water in South Africa has had a significant impact on the beneficiation and value addition of South Africa’s ores – particularly in the case of coal and gold. Professor Rosemary Falcon* discusses whether it is possible to upgrade ores in a water-scarce society.
processes, hence the difficulty in separating them in conventional processes based on density, whether in dry or wet circumstances.
New process This situation pertaind until a relatively new process appeared, which had been introduced into South Africa in
A
optical sorting using X-rays. This process
number of waterless
and in coalfields around the Ermelo and
separates out materials on the basis
processes designed to
Carolina areas.
of characteristics such as molecular
separate out desired products from their gangue minerals or
During the Second World War, SATMAR
structure, and in this matter, the light,
extracted such material to manufacture
highly aliphatic algal material was
host rock have been designed and tried
petrol. Several attempts at
selectively separated from the dense
out, but not until recently has significant
establishing mining and
success been achieved.
processing operations
Several investigations in recent years
molecular aromatic bituminous coal. This torbanite, based upon research
to extract torbanite
illustrate this progress in an exemplary
have been
manner. In the first instance, a special
made since
and highly valuable coal type known
that time, with
as torbanite was required to be
little success.
separated from the normal bituminous
Economics and
coal seam in which it was embedded.
the practical
For the record, torbanite is a shallow-
difficulty of
pan open-water coal composed of
separating the
abundant fossil algae (similar to the
torbanite bands
algal scum floating in stagnant pools
from the host
as seen today). In such cases, the algal
bituminous coals have
bodies are intimately mixed with very
proved to be stumbling
fine clay, i.e. the dust that settled at the
blocks. The difficulty in separation
Witwatersrand gold ore. Automated
bottom of the pond with the algal ooze
arose because of the combined density
optical- and radiometric-sorting
over time.
of the clay material intimately mixed
plants treating Witwatersrand gold
with the lightweight algal material.
ore were operational in the 1970s and
capacity of the algae to yield high
Together, the two components produce
1980s with limited success on ROM
quantities of high-value hydrocarbons,
a density equal to that of normal
applications. Since that time, sensor-
namely, volatiles, oils, tars and bitumen
moderate- to low-ash bituminous coals.
based sorting technology has evolved
when heated to modest temperatures in
Both bituminous coal and torbanite,
significantly in its detection capabilities
a pyrolysing (inert) atmosphere. Coals of
therefore, report to the same density
and throughput capacities of the
this type are well known in Mpumalanga
fraction in heavy-media beneficiation
sorting machines.
The value of such material lies in the
20
recent years – namely, sensor-based
Ins i de Mi n i n g 0 5 | 2 0 1 7
The difficulty of separating torbanite from host bituminous coals has been a stumbling block
undertaken in this equipment, was successfully and uniquely separated from coal using dual-energy X-ray transmissions. This research was continued by applying similar
sensor-based sorting technology to the treating of
Fossil Fuel Foundation Optical sorting methods have also been installed at one or more coal-fired power stations where pre-beneficiation using sensor-based sorting has successfully separated contaminating host rock from coal prior to entry of the coal into the milling circuit. This has led, in turn, to significant improvements in mill wear (notably reduced abrasion) and improved coal qualities entering the boilers. And this has led to better combustion efficiencies and reduced CO2 and greenhouse
part of a standalone process plant for
gas emissions during the course of
treating surface rock dump material.
power generation.
particular to recover misplaced reef
Pre-beneficiation
this country and its mining industry that
from surface waste rock dumps, i.e.
A second case study dealt with testing
South Africans can be so proud.
sorting gold reef from Witwatersrand-
waste rock sorting from ROM ore. The
type conglomerate. In one case,
ore body suffered 30% to 60% waste
*Professor Rosemary
typically, the grade of a SRD ranged
dilution. Sensor-based sorting provided
Falcon is from the
between 0.5 g/t to 1.0 g/t of gold.
a pre-beneficiation process, thereby
School of Chemical
Optical sorting achieved product
eliminating coarse diluting rock from
and Metallurgical
grades of between 1 g/t and 5 g/t at
prime ore. In both case studies, the gold-
Engineering at the
a mass recovery of between 5% to 30%
bearing quartz conglomerate reef could
University of the Wit-
of feed. A 100 t/h optical sorter plant
be effectively separated from waste
watersrand, and the
was successfully installed at the mine as
rock by optical sorting techniques.
Fossil Fuel Foundation.
Over the last few years, some gold mines have shown renewed interest in this beneficiation technology, in
It is just such adaptations to suit
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Coal Economics
Latest status of
coal Looking at global statistics, thermal seaborne prices have increased from the beginning of 2016 to reach a high of more than US$100/t in November 2016. This has had an impact on all main producers/exporters – namely Indonesia, Australia, the US, South Africa and Colombia. By Xavier Prévost*
S
The revenue required to keep mines open and productive will come from a renewed and revitalised local market. The signs are already there as prices rise every year, and the last increment (2016-2017) was probably in the range of 40% to 60%.
Electricity As electricity prices increase (and they will) to become unreasonably high, the solution is the implementation of IPPs (small 300 MW to 600 MW independent power producers) using the abundant coal resources this country is endowed with. Another potential coal user is the small inland industry, now using Eskom’s electricity. If the price is exces-
outh African companies,
cannot be done, unless they also want
sive, installing boilers can produce
after suffering last year’s very
to deliver the final blow to our already
energy as a cheaper solution.
low prices, have now recov-
unstable economy.
ered partially. Richards Bay
In years to come, we will still export
Fortunately for us, the reaction to
some coal, especially to regions that
exports decreased but not excessively.
these unwise tactics has already been
Now the forecast points to further price
experienced as various sec-
East and Africa. Though
decreases to reach about $68/t by
tors of the economy have
tonnages will probably
2019. Most likely, because of a lack of
expressed their dissatisfac-
decrease, the remaining coal
demand, export figures will again de-
tion about policies that, if
should be absorbed by the
cline in 2017. While the big companies
executed, would not only
local industry.
have somewhat reduced exports, to
destroy the mines, but also
prevent further sharp reductions of in-
leave approximately 78 000
ternational thermal prices, the future of
coal mine workers unem-
coal is dominated by factors beyond
ployed and their families
the industry’s control.
destitute. The same was
Here in South Africa, although we
tried in the US by the previ-
*Xavier Prévost is a senior analyst at XMP Consulting.
are in some way protected by the
ous government, in lieu of
fact that Richards Bay serves several
“saving the environment”, only to be
markets and is, therefore, slightly better
rejected by the current president.
off than most other exporters, the long-
Coal exports, as stated, once
term estimates point to a continual
the best money-makers, are
drop in demand and prices.
now declining and can-
Are we then living the end-days
not expect to support
of the industry? In my opinion: not
the industry as in
necessarily. To survive economically,
years past.
this country needs coal. I can quote various articles written recently by energy experts, including Rob Jeffrey,
want it, such as Pakistan, the Middle
To survive economically, this country needs coal
a well-known economist and specialist in energy. These say that, despite recent rumours of government and parastatals planning to replace coal as the main source of energy with renewables and/or nuclear power, it
In sid e M in in g 0 5 | 2017
23
Life blood
of materials handling
A
four-decade partnership between Powermite, which is part of the Hudaco Group, and French multi-
national Delachaux to distribute Conductix festoon systems, cable reeling
ABOVE Cable festoon systems from Powermite for efficient feeding of power, data, air, or fluids
drums (CRDs) and slip-ring housings to the Southern African mining industry has proven to be quite the dynamic duo. “Drawing on Powermite and Conductix-Wampfler’s combined 100-plus years of experience in electrification systems, the modular design of our light-, medium- and heavy-duty festoon systems incorporates state-of-the-art, world-class technology,” says Donovan Marks, marketing director, Powermite. Festoon systems feed energy, data, air or fluids to these various machines to keep them moving. As operations such as open-cast and underground
The Diamond Track System from Powermite is specially engineered to prevent dirt build-up mines, quarries, stockyards, and ports greatly depend on the reliable operation of these machines, the resulting equipment longevity, uptime and high productivity levels are fundamental to sustainable production and subsequently profitability. “Benefits delivered to customers and end users include above-average operational life, easy installation, uncomplicated operation and cost-effective maintenance with subsequent lowest possible operational and ownership costs and rapid return on investment. “No matter how extreme and arduous the conditions, it is paramount that festoon systems maintain a reliable, efficient, seamless and uninterrupted feed to machinery at all cost,” states Marks. “Our specialised festoon systems set the benchmark in quality and rugged reliability because there can simply be no compromise.”
24
Ins i de Mi n i n g 0 4 | 2 0 1 7
materials handling
Conveyor belt efficiency Increasing production has been one of the top priorities for mines for a while. An area that is sometimes overlooked is increasing the efficiency of conveyor belts transporting material over distances.
T
he technical paper ‘Increasing
the conveyor belt system through one
efficiency of conveyor belt trans-
ore pass connecting all Merensky Reef
porting system 4 Belt Lonmin’, by
levels to the sub-inclined shaft.
GG Le Roux, investigates various
The author collected information
options for increasing the efficiency of
about the conveyor belt
the conveyor belt transporting system at
system to determine
Lonmin’s Markana operation. The investi-
the design capacity
gation was to prevent the occurrence of
of the system to
a bottleneck at the main ore passes de-
achieve the objec-
livering ore to the conveyor belt system.
tive of the study.
“The conveyor belt system used at 4
Then, the author
Belt, Lonmin, consists of four conveyor
looked at various
belts operating in an electrical inter-
elements, such as
locked system. Currently, reef and waste
the capacity of the
materials are delivered to three of the
system of electrical
conveyor belts from six different levels,
interlocked conveyor
one level at a time,” writes the author.
belts, belt tensions and
He adds that the system is used for the transportation of UG2 Reef, Merensky
• tipping from two ore passes on the belt concurrently • increasing the available drive unit power • increasing the feed rate from vibratory feeders
The option of concurrent tipping would decrease the time necessary to empty out all of the ore passes
power requirements, and hoisting times.
•c hanging belt width/ belt specifications.
Conclusions The author came to a few conclusions after assessing various options that could increase the efficiency of the
conveyor belt transporting system that is used at 4 Belt.
He also discussed available options to
“The preferred option was the concur-
waste materials are delivered to the
increase the efficiency of the conveyor
rent tipping from two or more ore passes
conveyor belt system through ore passes
belt transporting system, and the follow-
to the conveyor belt system. The reason
connecting the sub-inclined shaft to all
ing were assessed in increasing the effi-
for this choice is that, if ore can be de-
operating levels. Merensky Reef material
ciency of the conveyor belt system:
livered from the ore passes to the belt
from all operating levels is delivered to
• varying the conveyor speed
system according to the schedule, less
Reef and waste materials. UG2 reef and
In sid e M in in g 0 5 | 2017
25
Are you sure you have the best possible solution for your belt conveying system?
Tel: Email: Website:
011 741 2500 info@rematiptop.co.za www.rema-tiptop.co.za
Physical Address: 22 - 24 Lincoln Road, Industrial Site, Benoni
materials handling time will be needed to empty out all the ore passes. “The method of concurrent tipping
table 1 Conveyor belt system data (summary)
R1 Conveyor
R1a Conveyor
R1b Conveyor
R2 Conveyor
from two ore passes will also result in the
Belt width (m)
1.2
1.2
1.2
1.2
added advantage that the amount of
Belt speed (m/s)
1.5
1.5
1.5
1.5
Belt length (m; slope)
804
442
500
582.2
Belt capacity (t/h)
770
960
850
720
Inclination (degrees)
12
12
12
12
ore in ore passes from two levels will be reduced concurrently, thus creating space for ore to be delivered to these ore passes and resulting in more fluent operation conditions on the different levels themselves,” writes the author.
Rock Characteristics
He adds that, when comparing the
Ug2
Merensky
Waste
3.91
3.17
1.8
Material size (mm)
300 x 350
300 x 350
300 x 350
Moisture factor (%)
10
10
10
option of concurrent tipping with the other options available, it can be clearly seen that all the other options available require more adjustments to the existing system. Therefore, the option of concurrent tipping is preferable to the other
In situ density (t/m3)
available options since all adjustments made to the system will cause significant downtime for the installation of bigger drive units, wider belts, bigger size idlers, changes in structure, etc. than the installation of a simple automation programme on the chutes from the ore passes that can be run from the control room. “From the report, it can be seen that concurrent tipping
A more efficient conveyor belt transporting system will ensure more fluent mining operations
would decrease the time necessary to empty out all of the ore passes and, therefore, increase the efficiency of the conveyor belt transporting system. A more efficient conveyor belt transporting system will ensure more fluent mining operations since the limited surge capacity will be utilised more effectively,” writes the author.
Recommendations He explains that the initial design of a mine or shaft is important. “The shaft must be designed for the maximum production rate that may be achieved through the life of the shaft. The particular scenario of 4 Belt shows that a shaft must consist of adequate surge capacity to prevent the occurrence of
table 2 Conveyor belt system capacities (derived from motor power calculations)
R1 Conveyor
R1a Conveyor
R1b Conveyor
R2 Conveyor
Mass of belt (kg/m)
36.2
36.2
36.2
36.2
Length of conveyor (m)
804
442
500
582
Inclination (degrees)
12
12
12
12
Shaft power (kW)
436
296
296
296
Belt speed (m/s)
1.5
1.5
1.5
1.5
Friction
0.04
0.04
0.04
0.04
Height component (m)
167
92
104
121
Capacity (t/h)
771
960
844
721
bottlenecks in the ore path out of the mine. If adequate surge capacity is not
used needs to be altered. All alterations
the option that would cause the least
provided in the initial design of the shaft,
to the transportation system used in an
amount of downtime in the operating
the situation being experienced at Ka-
operating shaft will cause significant
shaft should be chosen,” concludes
ree Belt is likely to occur.
downtime in the shaft and, therefore,
the author.
“Since the creation of additional surge
loss of production, which should be
capacity is nearly impossible on an op-
avoided at all costs. If alterations to
erating shaft, the transportation system
the transporting system are necessary,
Read this technical paper: www.saimm. co.za/Journal/v108n04p189.pdf
In sid e M in in g 0 5 4 | 2017
27
drilling & blasting
Transparency
The next frontier In the endless quest for the perfect daily blast, there are now some game-changing innovations being made to render activities at the underground stope face much more transparent to management on surface.
By Selwyn Pearton*
of information underground – through
S
and detonated, management can
pump controllers, for instance – by mon-
now gain unprecedented insights into
itoring and recording all activities under-
outh Africa’s challenging un-
the quality of work being conducted at
taken through the pumping units. This
derground mining environment
the rock face – and this can be done in
includes the number of holes charged
is made all the more difficult by
real time.
per face, the mass of emulsion that has
the lack of real-time information
flow about what exactly is taking place
Innovative technologies
underground from minute to minute,
BME has developed innovative technol-
and hour to hour.
ogies to bring the benefits of emulsions
Perhaps for the first time, mines are now
mass per face, and the amount of wastage per face. Even the utilisation of charging units
to the underground environment, even
can be monitored, so that manage-
able to manage underground blasting
in narrow-reef operations where mech-
ment can see exactly when a team
operations using objective metrics, or
anisation is difficult. Here, the use of its
was charging any particular face, the
measured indicators of best practice.
highly stable Megapump emulsion is
pace at which they were charging,
This has, in the past, been a significant
now well established in conjunction with
and the standing time of the units. This
challenge, because lines of communi-
handheld, lightweight portable charg-
data allows management to scrutinise
cation between personnel underground
ing units (PCUs). These innovations have
particularly those faces that have expe-
and managers on surface have tradi-
paved the way for better measurement
rienced sub-optimal blasting results, and
tionally been poor.
of key blasting parameters.
investigate for any abnormalities in the
By measuring key elements of when and how blast holes are drilled, charged
28
been used to charge each hole, the
Ins i de Mi n i n g 0 5 | 2 0 1 7
Building on our electronic detonation system, we can now gather a great deal
charging practice before detonation took place.
drilling & blasting
Also, data can be captured through mobile devices like tablets, which operators can use to photograph and audit the work-face,
The next challenge is to ensure that the data from underground is presented in a manner that is easy to access and relevant to the management function
report incidents under-
tion-related
feeding more information into the
challenges
system, this allows managers to identify
could usu-
underperforming areas so that they can
ally only be reported and managed on surface at the
end of a shift – so
ground, report breakdowns and
decision-makers were
downtime, and log safety issues.
not really able to take imme-
The centralised blasting system (CBS)
target their selective retraining efforts where they are needed.
User friendly To make this information user friendly, the system is able to turn that data into trends that help management to ana-
diate action that could save time and
lyse all the key processes and activities
was initially adapted for underground
facilitate efficiency. Instead, the delays
underground. The system can then be
applications so that the user could stand
would often result in lost blasts and
set up to generate reports on the trends
in the control room at the shaft head
lost production.
that management wants to focus on.
and detonate all panels underground
Of course, the next challenge is to
At the heart of our business is the
simultaneously at the flick of a switch.
ensure that the data from underground
reporting of blast performance and
With the enhanced CBS, the same net-
is presented in a manner that is easy to
production challenges, to ensure con-
The three boxes in the centralised blasting system work of communication cables – copper
access and relevant to the manage-
tinuous improvement of blasting effi-
or fibre-optic – that drives the central-
ment function.
ciencies. To do this, it is vital to create a
ised blast also carries copious amounts
To achieve this, we developed a new
transparent environment underground,
CBS to include a reporting platform.
so that performance of blasting teams
This allows users to log on to the internet
can be accurately measured in ways
and monitor the situation underground
that facilitate accountability and
Three different box types are employed
in real time; they can see, for instance,
constructive evaluation.
in the system: the control box on sur-
the status of charging activities and ex-
It is only by constantly measuring un-
face, the section boxes at underground
actly which of the boxes underground
derground blasting practices, and eval-
sections, and the blast boxes in the indi-
are primed and ready for blasting. The
uating them in terms of the quality of
vidual raise lines.
system can, therefore, be monitored
the blasts, that mines can move mean-
from a remote location, to check that
ingfully towards addressing root causes
everything is going as planned.
in any productivity deficiencies. By
of operational data to and from surface.
Boxes
Where we integrate the CBS and our blast log information system is at the blasting boxes, which can be set up as
As an information management sys-
harnessing the potential of new blasting
Wi-Fi hotspots to collect information from
tem, Blastlog can monitor trends and
innovations, data gathering tools, and
the pump controllers and mobile de-
performance in the underground en-
modern information and communication
vices – and send that information back
vironment. This allows management to
technology, we can make substantial
to surface.
view key indicators of blast-related per-
progress on the road to safer and more
formance underground – while the work
productive operations.
This presents a considerable step forward in overcoming the age-old prob-
is actually taking place.
lem of delayed reaction times in under-
In addition to that, because there are
ground operations. In the past, produc-
more data-collection points underground
*Selwyn Pearton is the regional manager: Underground at BME.
In sid e M in in g 0 5 | 2017
29
Pipes, pumps, & valves
The importance of Conventional bulk materials transport is giving way to longdistance slurry pipeline transport, which is now a proven technology. In tailings transport and mine backfill, valve performance plays a critical role in the efficiency of the entire system. Improper valve selection can cause excessive downtime. By Julien van Niekerk*
valve selection W ith the trend being the
of ore and ferrosilicon. The media and
pumping of slurry over
process properties vary in different parts
longer distances at higher
of the extraction process. In metal extrac-
solids concentrations, this
tion mines and plants, one will typically
statement has never been more relevant,
find abrasive slurries in the milling, cyclone
and slurry valves are truly being put to the
and DMS circuits and again at concen-
test in the resulting severe applications
tration feed and tailings, and to a lesser
that are often high pressure and highly
degree at flotation and thickener areas.
abrasive. In addition to these challenges,
Particle size, shape, hardness and den-
certain mines also have the added prob-
sity play an important role, as well as the
lem of the media being corrosive.
angle of impact on the wear surface.
In general, engineers designing for pro-
Pumping the media at a high solids con-
cess efficiency will often find that material
centration, pressure or velocity also leads
and equipment capabilities pose the
to elevated levels of abrasion. When
most serious limitations on allowable pro-
throttling abrasive media, the wear ef-
cess conditions, curbing efficiency.
fects are also exacerbated.
Abrasive materials
best not to install valves on the bend of
The most abrasive materials found in the
a pipe, or on a Y-joint. It is also important
mining industry are slurries from hard types
to consider whether the application is
If the transported media is abrasive, it is
It is important to consider whether the application is bidirectional or unidirectional bidirectional or unidirec-
trained water vapor or suspended abrasive
tional, and ensure that the valve is installed in accordance with the installation instructions provided.
where high-pressure media contains en-
particles. It combines the
Factors impacting wear surface • • • •
Particle size Shape H ardness and density play A ngle of impact on the wear surface
control accuracy of a globe valve with the strength of a severe-service
to reach installations. This also prevents
ient to use, but can pose problems for
ball valve. The valve is available with a
tampering and unauthorised entry to
certain gasket-free or integrated-gasket
tungsten carbide or heat treated nickel
the equipment.
valve designs. It is best to investigate the
overlay plug.
Rubber lined gaskets may be conven-
valve gasket requirements in the early
There is also the Bray Series 39L ceramic
Materials technology directly influences the valve industry. Advanced materials
project phase to ensure that rubber lin-
butterfly control valve for highly erosive
and coatings are continuously being
ing is not applied on their mating pipe
slurry control. It features a single offset
developed and made available. But
flange faces.
disc that is available in hardened chro-
even though innovation can be rapid,
moly iron and partially stabilised zirconia
market readiness is important and resist-
portant to not only look at the process
ceramic. It is also available with ceramic
ance to change can be a large obstacle
conditions, but also consider the general
liners and other hardened alloy liners.
to advancement.
installation environment. For example,
There are various other valves for the
the media might not be corrosive, but
most abrasive isolation applications on
Specialists
the environment might well be.
offer as well.
Valve specialists can help to identify
When doing a valve selection, it is im-
It is always best to use full port valves in
suitability issues early on, and it is best to
slurry applications. Valves with a torturous
New technology
flow path or an element directly in the
Our company offers customers the op-
able to offer the best solution for the most
flow path, such as butterfly, globe and
tion of using remote mount electro-pneu-
challenging applications. Working closely
weir-type diaphragm valves, will wear
matic positioners, rather than having the
with a specialist valve supplier will cer-
prematurely in slurry applications. This
positioner mounted directly on the valve.
tainly help to reduce cost of ownership
again refers back to valve selection.
The positioner and its complementing air
and downtime.
involve them from the start. They will be
preparation equipment are supplied in a
Also, it is important to inspect valves
plug-and-play stainless steel pneumatic
regularly so that early signs of wear and
There are unique products on offer when
enclosure that can be custom made
failure can be detected and the valve
the requirement is the throttling of an
according to individual requirements.
can be maintained or repaired before it
abrasive media. The DeZURIK RCV rotary
Mounting the positioners remotely in en-
becomes irreparable.
control valve has been specially engi-
closures helps to protect the positioner
neered for extremely precise throttling
from environmental damage, and is ide-
*Julien van Niekerk is a director at
control in severe-service applications
al when valves are in hazardous or hard
AR Controls.
Ideal valves
In sid e M in in g 0 5 | 2017
31
energy efficiency
Oiling
power transformers Stable power generation is a critical challenge for Africa due to the fact that most countries in sub-Saharan Africa have an electrification level below 30%. Modern power transformers are getting smaller but operate at higher voltages, which results in greater stress being placed on oil. By Tendani Ndwamise*
P
long-life, high-performance oil with zero sulfur. ower transformers are es-
The new range helps to meet indus-
sential in most mines as they are
try challenges in the power sector
used to reduce or increase the
by improving transformer perfor-
voltage of alternating current.
mance compared to conventional
These transformers are expensive, but
mineral oils. The range helps to reduce
essential business assets; transformer
operating temperatures, and offers
understanding how to create the best
failures can often be catastrophic and
longer oil life and excellent resistance
lubricants possible.
result in severe power interruptions that
to degradation. It is also easy to use
could cause economic losses.
due to the oils being fully miscible and
Power transformers
compatible with other transformer oils,
The average age of transformers in
recently launched a new range of
as well as all materials used in trans-
many countries varies between 30 to 40
electrical oils, known as Shell Diala S4
former construction. Of course, this is
years, and many companies are operat-
ZX-I, for power transformers, which is
an oversimplification of why oil is impor-
ing these units close to and beyond their
the latest inhibitor oil from Shell and a
tant because there are several types
expected lifespans. Because it costs up
very important one too, because Shell’s
of lubricants for different applications,
to $4 million for a replacement, there is
cutting-edge GTL technology offers a
and a great deal of research goes into
an economic incentive to keep them
Shell, a BBBEE Level 1 contributor,
Helping improve efficiency with next-generation transformer oils Shell GTL base oil when compared to traditional mineral oils High viscosity index
Benefits of Shell Diala S4 range of transformer oils
32
Lower volatility
Extended oil life
Ins i de Mi n i n g 0 5 | 2 0 1 7
Better additive response when additivated
Transformer protection
Better oxidation stability
Transformer efficiency
One should choose a lubricant that has been designed to ensure that the equipment is protected and works productively
the oil on transformer ageing and reliability.” The Shell Diala S4 range of
improved in order to
oils was, therefore, designed
running. When choosing an oil for person-
produce transformer
al or industrial applications, it’s prudent
oil that could extend the
to remember that every part of the ma-
lifespan of transformers, provide
chine, or process, has been meticulously
enhanced protection and result in great-
engineered and one should, therefore,
er efficiency. One test during the research
Power for sustainable growth
choose a lubricant that has been de-
simulated the effects of high-voltage tran-
Investing in reliable power generation
signed to ensure that the equipment is
sients due to lightning strikes and switch-
facilities across Africa has the long-
protected and works productively.
ing operations in power systems, and
term benefit of creating jobs and fos-
assessing the resilience of different oils in
tering economic development and
such a scenario.
growth. GTL-based transformer oils have
In the world of power distribution, the optimal functioning of equipment is extremely important because failures lead
Zhongdong Wang, professor of high
to meet a variety of challenges presented by high-voltage transformers.
an excellent response to antioxidant
to high repair bills, long downtime and
voltage engineering, University of
additives, meaning that they resist deg-
possible safety risks. It is for these reasons
Manchester, said: “When considering
radation in demanding applications;
that Shell has been investing in research
safety, environment and economic im-
essentially, this means transformers can
programmes with leading universities,
pacts, the implications of a transformer
keep working for longer, as their compo-
technical institutions and private com-
failure can be extremely severe for a
nents are protected.
panies to investigate transformer design
power utility, especially one that owns,
and the influence that oil has on the reli-
operates and maintains a population
ability of such equipment.
of ageing transformers. Therefore, it is of
One of the goals of the research was
vital importance to understand trans-
to identify key attributes that could be
former reliability and the influence of
WHY GTL?
Base oil produced from purified natural gas at a molecular level results in a significantly more consistent and stable product than conventional base oils
To find out how Shell Lubricants can help you power tomorrow, go to shell.com/lubricants *Tendani Ndwamise is the marketing manager at Shell Lubricants.
Changes to transformer technology and operation place increasing demands on transformer oils • Higher voltages to improve transmission efficiencies over longer distances • Higher power to weight and volume ratios to reduce manufacturing and installation costs • More frequent operation under overload and less redundancy in case of failure • Higher operating temperatures – expectations for a longer transformer operating life than ever before
In sid e M in in g 0 5 | 2017
33
LEGAL
s e n i l e h t n e e w t e b g n i d a Re
A legal dispute between an Australian mining company and the Department of Environmental Affairs recently raised important implications of the One Environmental System (OES). This system transfers the responsibility for granting, monitoring and enforcing the conditions of environmental authorisations for prospecting and mining operations to the Department of Mineral Resources.
By Garyn Rapson*
34
Ins i de Mi n i n g 0 5 | 2 0 1 7
T
he Western Cape High
has given exclusive compliance author-
Court recently handed
ity in respect of mining operations to the
down judgement in re-
Department of Mineral Resources (DMR).
spect of an Australian min-
The DEA argued that environmental au-
ing company’s allegedly illegal
thorities maintain certain oversight func-
activities at its West Coast Tormin
tions under NEMA, and that the mine’s
Mine. In this matter, following a
interpretation of NEMA would result in
number of complaints from indi-
far-reaching curtailment of its powers.
viduals and organisations about the mine’s alleged lack of com-
Unlawful
pliance with and transgression of
The Western Cape High Court found
its environmental management
that the search and seizure operations
programme, environmental in-
by environmental inspectors of the DEA
spectors from the Department of
and DEADP were unlawful as NEMA
Environmental Affairs (DEA) led a
provides that the mandate to carry out
search and seizure operation. The
compliance inspections at mining oper-
operation resulted in the laying
ations is to be fulfilled by environmental
of criminal charges against the
inspectors appointed by the Minister of
mine in respect of certain trans-
Mineral Resources.
gressions, including actions that
review application, in which it
Reading between the lines of the judgement, the court expressed the following views:
argued that the DEA, and the
• T here is no clear delineation between
led to the collapse of a sea cliff. The mine brought a High Court
Western Cape Department of En-
the mandate of environmental in-
vironmental Affairs and Develop-
spectors appointed by the Minister of
ment Planning (DEADP), lacked
Environmental Affairs and the Minister
any legal jurisdiction to monitor
of Mineral Resources, where environ-
and enforce compliance with
mental degradation is not related to
the mine’s environmental man-
non-compliance with an environmen-
agement programme as the OES
tal authorisation issued in respect of
LEGAL activities directly related to mining.
such as the National Environmental
provisions of the OES, the court con-
It is clear that the Minister of Mineral
Management: Integrated Coastal
templated whether an approval
Resources is the competent authority
Management Act (No. 24 of 2008) in
of an amendment to an environ-
in respect of listed activities that di-
this case. Other such environmental
mental management programme
rectly relate to mining and prospect in-
Acts include NEMBA, NEMPAA, NEM-
under the provisions of the MPRDA,
spectors appointed by the Minister of
WA (to the extent that the activities
which was pending when the OES
Mineral Resources are mandated to
are not mining related) and NEMAQA.
came into force, could be irregu-
investigate non-compliance in respect
We are of the view that it is likely that
lar and open to challenge as the
of environmental authorisations for
the DEA will increase its compliance
transitional arrangements don’t
such activities. The court, however,
efforts in respect of these Acts where
adequately cater for pending
was reluctant to opine on whether
its environmental inspectors have
the investigation of general environ-
sole jurisdiction
mental degradation, which does not
• MPRDA environmental manage-
amendment applications. The judgement highlights the importance of following due legal process.
arise from non-compliance with an
ment programme approvals that,
All applications should be scrutinised
environmental authorisation issued for
under the OES, are considered to be
with a legal eye to ensure that sub-
listed activities directly related to
NEMA environmental authorisations
stantive and procedural requirements
mining or prospecting, but occurs in
(as of 8 December 2014) do not apply
prescribed by law have been satisfied.
a mining area, falls within the exclu-
retrospectively. If NEMA-listed activities
It also highlights the growing turf war
sive jurisdiction of the Minister of Miner-
were commenced with prior to the
between the DMR and the
al Resources.
OES transition, they remain unlawful
DEA in enforcing compli-
Accordingly, the door remains open
and are not cured as a result of the
ance on mining areas.
for the DEA to retain oversight for cer-
transitional arrangement
tain environmental offences that may occur as a result of mining activities
• Although there was no clear pronouncement on the transitional
*Garyn Rapson is a partner at Webber Wentzel.
(this too will need to be tested in court) • T he DEA retains oversight of environmental Acts unaffected by the changes to NEMA under the OES,
The judgement highlights the importance of following due legal process
MARKET news
market news
from around the continent Workmen safety and comfort considered in QES range Common to generator failures is inadequate battery life or power. Atlas Copco has released its most efficient generator yet, to seamlessly deliver power no matter how stringent the conditions. “The QES range of mobile generators presents the most practical, predictable power choice currently available on the market,” according to David Stanford, business line manager: Construction Technique’s Portable Energy, Atlas Copco. Fitted with larger capacity fuel tanks, the QES generators can run for a full eight-hour shift and offer up to 400 hours of granted autonomy at full load before requiring refuelling, depending on the fuel tank configuration.
The externally fitted fuel-fill cap speeds up the refuelling process and there is also an option to connect to an external fuel tank.
requirements of the mining and construction industries. Superior-quality components contribute to extended generator life cycles and
The range has been extended from 9 kVA to 200 kVA and now comprises 11 models to meet the standby power
Atlas Copco mobile QES generators offer predictable power when it’s needed, where it’s needed
subsequent improved uptime and reduced maintenance costs; the fitment of dual-stage heavy-duty air and fuel filters doubles engine life. The rugged galvanised steel enclosure provides protection against tough environmental elements. “Standard features such as a spillage-free frame (110% containment) and a 500-hour service interval with short service routines of under two hours help to maximise uptime, production and productivity levels on the job site,” adds Stanford. “The canopy version can also withstand corrosion for up to 10 years.” Further extensions are planned for the range.
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Real-time, rugged gas monitoring
Rene Rusch, CEO of ELSO Holdings, with Rondhir Haripersad, GM for Africa, Goscor
Cleaning the mining industry, one step at a time The Namibian market is picking up, especially with the recent discovery of large platinum deposits in the Swakopmund area. It makes sense then that one of the oldest, environmentally aware cleaning product manufacturers in Namibia, Elso Holdings, has partnered with Goscor Cleaning Equipment (GCE) to extend its footprint in the mining industry. For both companies, the partnership represents the next stage of their growth strategies and product portfolios for the Namibian region. While explaining the motivation behind the partnership, Greg Venter, general manager, GCE, explains, “Namibia’s US$86 million Walvis Bay port expansion project by developer China Harbour and Engineering Company (CHEC) is on target to be completed by May 2017. The ambitious project will create a new island from reclaimed land,
and almost double container capacity from the current 375 000 TEUs a year to 650 000 upon completion. Covering 40 ha, the new terminal will have a quay length of 2 100 m.” This represents “an important growth market for us and, in tandem with Elso Holdings, we will be ideally positioned to take advantage of all of these opportunities,” Peter Esterhuizen, national sales manager, GCE, adds. The main brands to be distributed across Elso Holdings’ seven locations in the region are Ghibli, a leading manufacturer of wet and dry commercial vacuum cleaners and scrubbers, and Delfin industrial vacuum cleaners and suction units for solving particular material cleaning and recycling problems. The flagship product range to be distributed by Elso Holdings, however, is GCE’s Tennant range.
A new technological benchmark has been set by MSA Africa and its multigas detector system. The new MSA ALTAIR 4XR multigas detector provides real-time event notification using Bluetooth connectivity. The multigas detector was officially launched at the Secunda Petrochemical Roadshow, boasting advanced features, which include health and safety for workers operating in hazardous or dangerous environments. The tough and reliable four-gas monitor is among the fastest in the world, sensing gas two times faster than the industry average. “MSA XCell Sensors are The new MSA ALTAIR 4XR multigas detector unparalleled in today’s market, enabling faster response times, shorter span calibrations and longer life, saving you time and money,” reveals Suraksha Mohun, product marketing manager, MSA Africa. When paired with the MSA ALTAIR Connect app, available from the Google Play store, it can text alarm notifications immediately to supervisors, team members or other users. “Maintenance, operational support, and compliance are quickly and reliably enhanced, while real-time alarm and event notifications let you deliver an entirely new level of safety,” Mohun comments. The ALTAIR 4XR multigas detector is MSA Africa’s most rugged gas detector yet. It can survive 25 drops from 1.2 m, an incidental 7.5 m drop onto concrete, has a military-grade rating (MIL-STD-810G), and an IP68 dust- and waterproof rating (2 m for at least an hour). It has an operating temperature range of -40°C to 60°C.
Severe Duty Special Applications special risk fire protection
Celebrating
25 Years Yea
1990 tto o 2015 20
Sev Severe Duty Monitor washdown, dust Continuous use applications, vehicle veh st suppression & fire fighting. 2900 L/min @ 5 - 14 bar
+27 (0) 861 111 544 Mi Mike: +27 (0) 83 251 9346 mgf@dosetech.co.za • www.dosetech.co.za
market news A Derrick HI-G performance linear motion dewatering screen in operation
Effective mine water management strategies
A bank of Kwatani single-deck exciter-driven dewatering screens in a mineral sands application
With South Africa’s recent water scarcity hitting the headlines, mines have had to confront the reality of water shortages by implementing effective mine water management strategies to conserve and recycle water, particularly in their process plants, which are often among the most water-intensive operations on-site. “Dewatering screens are playing an increasingly vital role in this regard,” according to Kim Schoepflin, CEO, Kwatani. “Rather than pumping slurry out into tailings dams – where water is lost through evaporation – mines today will generally aim to get their waste as dry as possible before disposal. “This allows for better recovery of water, while tailings can be disposed of through dry-stacking or as backfill; this both conserves water and protects the environment from water-borne pollution.” Kwatani, the vibrating screen and feeder specialist, notes that using dewatering vibrating screens adds particular value to the commodity being mined, by efficiently extracting recyclable water from the desired end product to cut transport costs and ensure compliance with sales specifications. The dewatering screen drains “free moisture” from a wet slurry through the screen media while retaining as much of the fine particle material in the screen bed, creating a product that can be
As the screen vibrates, the G-forces enhance the adherence of the particles to one another, effectively squeezing water out of the material. At the same time, the linear action of the screen conveys the cake up the slightly inclined deck, which, on Kwatani dewatering screens, can be up to a five-degree angle. “Our in-house designed and constructed Kwatani screens achieve higher G-forces by generating an ideal combination of stroke and speed, which, in turn, squeezes more water out of the bed,” notes Schoepflin.
conveyed and stockpiled with minimal handling and environmental impact. The drained moisture can then be reused by being recirculated into the processing plant. Kwatani’s dewatering technology works by trapping solid fine particles in a thick layer on the screen, creating a “cake” that acts as a filtration bed. The incoming feed forms a pool in the angle between the back of the screen and the slightly upward-sloping deck, where most drainage takes place until the feed particles form a cake.
A Kwatani single-deck exciter-driven dewatering screen with tee-pee-shaped panels in Kwatani’s works
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market news
The overflow arrangement of a Reflux Classifier in a coal application
A multiple Reflux Classifier installation
Feeder technology growing in coal processing Traditional technology cannot accommodate varying feed conditions, which are a reality in mining operations. These feed variations often result in recovery losses in coal processing applications because of the inability to handle these conditions. The Reflux Classifier (RC) from FLSMidth is a lot more forgiving of solids feed-rate variations. It allows a consistent separation of materials and as a result higher separation efficiency. Terence Osborn, commercial manager: Minerals Sub-Saharan Africa, FLSmidth, says, “As the coal processing industry has grown in Mozambique, so too has the
adoption of FLSmidth’s RC technology by multiple mines in the country.” Each of these units now installed and commissioned in coal applications in the Waterberg and in Mozambique is capable of treating approximately 200 tph of raw fine coal. “Significantly, the success achieved by the RC technology in the second phase of this coal processing plant has resulted in RC being chosen as the technology of choice for retrofits to the original plant. Prior to this, test work was conducted on-site by FLSmidth using its mobile test RC 300 rig to validate the expected performance of the larger RC units,” he concludes.
The underflow arrangement of a Reflux Classifier
Reflux Classifier plant
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