Inside Mining November/December 2013 by 3S Media

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MEDIA

AFRIC AN UPDATES ON THE

ining GROU GROUND ND D AAND ND U UNDERGROUND NDE RGRO U ND

HOT SSEAT EA

CEO Charles Sambo on Lehating Mining’s upcoming high-grade manganese operation P10

SSIS A AND ND G4 CIV CIVILS deliver BRPM north chairlift decline JUNIOR MINING Making it work in South Africa PIPES & PUMPS Presenting premier projects

SPECIAL FEATURE ENVIRONMENTAL RESPONSIBILITY Mining with care ISSN 1999-8872 • R40.00 (incl. VAT) • Vol. 6 • No. 11 • November/December 2013

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CONTENTS

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

GROUND AND UNDERGROUND

Highly commended 2012 PICA Cover of the Year - B2B Publishing MEDIA

AFRIC AN UPDATES ON THE

November/December 2013

EDITOR’S COMMENT

ENDORSED BY www.miningne.ws

ining

LQLQJ LLQ QLQJ GROUND DA AND U UNDERGROUND N D ERG G ROU O ND

HOT HO SEAT SSEA

CEO Charles Sambo on Lehating Mining’s upcoming high-grade manganese operation P10

SSIS SS SIS IS A AND ND ND G4 C G4 CIVILS CIV IV VIL ILS deliver BRPM north chairlift decline JUNIOR UNIOR U N OR O M MIN NING NI NG G Making it work in South Africa PIPES PIPES PES ES S & PUMP UM UMPS U MP PS P S Presenting premier projects

SPECIAL FEATURE

ON THE COVER O

Miners who love the environment do exist

FROM THE FOSSIL FUEL FOUNDATION

4 12

R Royal Bafokeng Platinum is iinvesting in the establishment of a new chairlift decline at o iits BRPM north shaft, aimed aat enhancing safety and iimproving production speed. TThe project can be described aas innovative, quick and low on capital costs thanks to o ccontractors SSIS and G4 Civils’ design/build construct. d

Comment from Andrew Kinghorn Major new high-value use for coal

HOT SEAT

Lehating Mining develops a manganese masterpiece

JUNIOR MINING

20 24 26

ENVIRONMENTAL RESPONSIBILITY Mining with care ISSN 1999-8872 • R40.00 (incl. VAT) • Vol. 6 • No. 11 • November/December 2013

Platmin’s success from its greatest geological challenge Wescoal makes the most of every opportunity Aquila Resources shows its faith in South Africa

29 SPECIAL FEATURE: ENVIRONMENTAL RESPONSIBILITY IN MINING

30 34 38 42 46 20

48 50

Legislation: the minefield around the mines An energy-biodiversity-coal nexus Linings laid for New Denmark Exploring new civils frontiers in mine waste Transdisciplinary collaboration leads to environmental responsibility Walking a fine line with mining wastewater The conservation key is valuing nature

PIPES & PUMPS

57 62 64 67

Piping from pit to port DRC’s pump patriarch Flowing mineral sands in Senegal A new look at PE pipe systems for mining

INSID E M INING 1 1 /1 2 | 2013

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EDITOR’S COMMENT

Publisher Elizabeth Shorten Editor Laura Cornish

MINERS WHO LOVE THE ENVIRONMENT

Senior journalist Vicky Sidler Head of design Frédérick Danton Senior designer Hayley Mendelow Designer Kirsty Galloway Chief sub-editor Claire Nozaïc Sub-editor Patience Gumbo

They do exist

Marketing & events coordinator Neo Sithole Client services & production manager Antois-Leigh Botma Production coordinator Jacqueline Modise Financial manager Andrew Lobban Administration Tonya Hebenton Distribution manager Nomsa Masina

Generally speaking, there is a misconception that mining and the environment are mutually exclusive. After all, you can’t be a miner and care for the environment, right? Wrong!

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

HE REALITY IS THAT the two worlds couldn’t be more directly connected or interlinked. In the ‘good old days’, and I mean many decades back, miners focused on mining and the environment generally suffered the consequences. Today, however, the likelihood of getting a new mining operation up and running without first implementing a wellthought-out and approved environment management programme is zero! This is really great news for our planet, as well as for our environmental lobbyists who make it their personal mission to make our mining industry’s lives ‘a little less easy’. Your job has become considerably easier I say. The mines really have their environmental responsibilities in hand and the government is ensuring this remains so. Can I just say, and this is simply my opinion, that lobbyists drive me crazy, quite literally. You can’t be anti-mining and enjoy the comforts of the modern world – electricity, a smartphone, a car, television… need I go on? The downside for our miners, and there sadly always is a downside, is that the mines have been put under such severe pressure to mine responsibly that the situation has shifted to the opposite end of the scale. Charlaine Baartjes, MD at EcoPartners, says that 77 environmental Acts have been promulgated between 1995 and 2014. In fact, environmental legislation has doubled every 20 years since the 1940s. Today there are 120 South African environmental Acts regulating the mining industry. “This is making it almost

impossible to comply with,” she states openly. “Our poor mining industry, it almost appears that it has been set up to fail.” Nonetheless, the mining industry should be hailed for its efforts to be environmentally compliant, despite the fact that it is getting more and more difficult to do so. Reassuringly, it is comforting to know that even in the past, before environmental legislation was little more than a small consideration, South Africa’s mining companies were showing respect for the country’s national heritage site. In the latter half of the 1970s, the state-owned steel company Iscor (which was subsequently split into Exxaro and Kumba Iron Ore) completed prospecting for coal in the Kruger National Park. While Internet research reveals some controversy around the situation, it appears “Iscor would not even consider the advisability or practicability of conducting mining operations in the reserve, apart from studying the geological survey’s drilling data pertaining to the Kruger National Park as they become available” (Journal of the South African Institute of Mining & Metallurgy, May 1978). Apparently, when the situation became publicly known towards the end of 1977, it aroused grave concern among both the public and conservation circles and became a highly emotive issue. Iscor ended up developing the Tshikondeni mine (now an Exxaro mine) to the north of the Luvuvhu River during the early 1980s. Before concluding, I would like to introduce our faithful readers to Inside Mining’s incoming editor, Gerhard Hope, who has joined the publication after a four-year stint in Dubai working on a successful weekly construction magazine. Over the years he has gained experience in the mining capital equipment field and is looking forward to taking Inside Mining forward and growing it further.

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INSID E M INING 1 1 /1 2 | 2013

FROM THE COAL PIT

By Andrew Kinghorn Director, Fossil Fuel Foundation

South Africa is facing a dramatic power crisis, exacerbated largely by the looming coal cliff. The size of the coal cliff ranges from 60 to 120 Mt and is expected to impact on the country between 2013 and 2019.

POWER CRISIS

Cliff hanger T

HIS CLIFF refers to either an overhang (oversupply of coal, but no power station to use it) or underhang (undersupply of coal, with power station empty). Of the four billion tonnes of coal that Eskom needs over the next 40 years, two billion tonnes will have to come from new sources (coal mines). At this stage we are only considering the coal cliff from a volume perspective. However, if coal qualities are included as another parameter, the size of the cliff increases. Eskom’s cents/kWh tariff has tripled from 20 c/kWh in 2003 to >60 c/kwh in 2013 (compared with an average price of 212 c/kwh for Independent Power Producers in 2013), and this price is expected to double in the next five years. So, not only does South Africa face a coal cliff, but also has a cost cliff to contend with. For example, Exxaro’s Groetegeluk coal mine has had coal

ready to supply to Eskom’s Medupi power station since 2011, as per its signed coal supply contract. However, due to the delay in construction of Medupi, Eskom has been unable to burn any of this coal for the past two years and might only have the capacity to burn a small quantity of it when the first set of Medupi comes on line late next year (2014) at a “guestimated” cost of nearly R200 billion – against an original target of R50 billion. This particular cliff has had three negative impacts. First, Eskom was not able to meet its supply requirements, which has led to load-shedding in the smelter sector. Second, there is an R8 billion buy-back option, which was rejected by NERSA. Third, and

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most damaging, with demand significantly exceeding supply, Eskom is avoiding uncontrolled blackouts only by running its diesel-driven opencycle gas turbines flat out at enormous cost, while simultaneously engaging in demand management and controlled load-shedding by exercising its interruptible contracts to large customers such as BHP Billiton, paying large energyintensive industrial users such as ferrochrome smelters to shut down and urging consumers to switch off everything possible. Not only does this cost Eskom dearly due to the enormous direct cost of diesel fuel and payments to smelters to shut down, but Eskom also loses the electricity sales revenue so desperately needed to meet its burgeoning costs, as a result of its inability to meet the country’s demand

was the responsibility of the state and, accordingly, would remain in government hands. He also said in the Department of Private Enterprise’s May 2013 Budget Vote that initiatives adding momentum to a “comprehensive industrialisation and transformation programme”, linked to the multibillion rand investment programmes of SOCs such as Eskom and Transnet, would be unveiled. He noted that there was an “unyielding political will” to ensure that black industrialists, miners and professionals were developed and nurtured through the procurement policies and programmes of the various SOCs falling under his authority. This unyielding position begs a couple of questions: Is there a direct relationship between the size of the cliff and the volume of rhetoric? Will this strategy result in a shift towards the dark night or towards the new dawn? Do we have the correct strategy in place to tackle a cliff of this size? Well-known strategist Clem Sunter points to three potential courses for South Africa in general, and they equally can be applied to the coal cliff: • All the ducks in a row – we get the required coal supply timeously at the right price. • None of the ducks in a row – we get the required coal supply timeously but at the wrong price, or we don’t get the required coal supply timeously but we do get it at the right price, • A failed state – we don’t get the required coal supply in time and it is at the wrong price (we have coal supplies in the Waterberg with no

South Africa should induce the privatisation of some of its stateowned assets to ease the financial and capacity strain on the government for electricity. To understand the cause and size of the coal cliff, we need to understand the primary contributing factors and a possible solution. Eskom is a state-owned company (SOC) and, as such, is governed by the ruling political party. The Public Enterprises Minister, Malusi Gigaba, last year stated that there were no plans to privatise either Transnet or Eskom, and no intention to split them. He added that infrastructure development

FROM THE COAL PIT

dedicated power stations and power stations in Mpumalanga with no dedicated coal supply, and a connecting rail link that is under capacity and running late at a transport rate that will have a significant impact on the Eskom power price). We also have a coal cliff at Richards Bay. Transnet carried out a study on a new coal terminal as part of the R30 billion Richards Bay investment plan. The programme director for the project, Sudesh Maharaj, says a conceptual study for the coal terminal has been completed as part of a government-backed plan to open up export capacity for emerging black coal miners. The new terminal is being proposed as an open-access facility. But Maharaj has acknowledged that Transnet’s studies proceeded on the basis of a mandate received from its leadership rather than on any analysis of whether there is commercial demand for the terminal. Richard Bay’s Coal Terminal has a theoretical annual nameplate capacity of 91 Mt, but operates well below that level owing to constraints on the rail channel from the Mpumalanga coalfields to the export facility. In August 2013, the Trade and Industry Minister, Rob Davies, announced cabinet approval of the building of a third coal-fired power station by Eskom, although timelines, schedules and costs have yet to be approved. This decision was taken based on Eskom spending approximately R240 billion on the Medupi and Kusile power stations – the lion’s share of a R300 billion budget to expand its generation capacity over 10 years. The construction of both stations has already been delayed by three years. If the

more accepted guestimate of a cost of R400 billion for the two power stations proves to be correct, where will the additional R160 billion needed for the completion of the two power stations come from? A possible solution to the problem lies in privatisation. The Industrial Development Corporation (IDC) chief economist, Lumkile Mondi, this year called for the debate around the privatisation of the country’s assets to be re-tabled – removing government’s current stranglehold on strategic assets on the back of disappointing performances by SOCs. “Increased revenue can only come from growth – if you can’t run it [the enterprise] efficiently, give it to someone who can,” he asserted. He cited continually delayed projects and their ever-rising costs, pointing to Eskom’s embattled energy expansion and rehabilitation plans. He also indicated that the development of South Africa’s rail system and the roll-out of new rolling stock could fare better in the hands of the private sector. South Africa should induce the privatisation of some of its state-owned assets to ease the financial and capacity strain on the government, while ensuring an injection of revenue into the state coffers. However, balanced state and private sector participation is required, as both have critical roles to play as the country develops and grows. Bad planning, the lack of transparency and unrealistic economic solutions surrounding the national energy planning can only serve to worsen the looming power crisis, and the coal cliff facing South Africa may well dictate which of Clem Sunter’s scenarios is more likely to play out.

IN S I D E MI N I N G 1 1 / 1 2 | 2 0 1 3

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COVER STORY

BRPM NORTH CHAIRLIFT DECLINE

SSIS and G4 Civils deliver Royal Bafokeng Platinum is investing in the establishment of a new chairlift decline at its Bafokeng Rasimone Platinum Mine (BRPM) north shaft, aimed at enhancing safety and improving production speed. The project can be described as innovative, quick and low on capital costs thanks to contractors SSIS and G4 Civils’ design/build construct, writes Laura Cornish.

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ROM JUNE 2014, every underground miner at BRPM north shaft will have access to the underground workings via a new decline chairlift. It will accommodate 550 people per hour travelling to their respective work areas and ensure their journey is a safe one. “Once complete, it will provide our employees with safer and faster access to the underground workings,” says Paul

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COVER STORY

innovative solution van Wyk, section manager at BRPM. Undertaking a project of this nature, in spite of poor platinum demand and weak platinum prices, has led to a design and build contract that is nothing short of impressive, from every aspect. Together with EPCM contractor DRA Mining, multidisciplinary engineering firm SSIS and civil engineering construction company G4 Civils presented BRPM

with a turnkey package for the installation development contract was completed. G4 Civils mining director, Quintin Badof a tunnel that, despite opposing traditional development methodologies, is still enhorst, explains the first critical project step and outlines quick to deliver its importance. and substan“Bulk earthtially lower works to estabin cost. lish the box cut “Unlike typwith temporary ical tunnel support were development , the first essenblasting and tial steps in the concrete lining project. It is the a decline, this Paul van Wyk, necessary platproject entails form required to the construcsection manager at BRPM install the tuntion of a box nel. Compared cut and the installation of a patented corrugated struc- to a permanent box cut, which is prone to tural steel 80 m long tunnel that has taken weathering, dewatering challenges and reonly a few months to complete,” explains quires lateral support upkeep, a closed box SSIS’s director, Dr Mark Webb. Once the cut is more viable, aesthetically pleasing tunnel is installed, the box cut will be and cost effective in the long term. “The design of the box cut is critical to filled, leaving no evidence of the tunnel the overall project as it must support and other than its entrance. The contract to develop the box cut was accommodate the tunnel in terms of angle, awarded in January 2013 and the contract length and support.” Installation of the tunnel was a short for the tunnel in March. In November, 11 months since project start, the decline three-day process. The 1.2 m long steel segments are transported to site and ‘inserted’ onto the demarcated tunnel area FAR LEFT Workers ensure the tunnel using an overhead crane. A small Bobcat is secure excavator pulls the assembled segments MIDDLE A Bobcat excavator pulls the into place and aligns them. SSIS is the tunnel segments into place and aligns them sub-Saharan African distributor for the BELOW Royal Bafokeng Platinum, DRA, SSIS and G4 Civils celebrate the successful steel product, which is manufactured in installation of the chairlift decline tunnel North America by Atlantic Industries

“Once complete, [the decline] will provide our employees with safer and faster access to the underground workings.”

TUNNEL STATISTICS AND DETAILS • 80 m tunnel length connecting directly with underground workings • multi-plate corrugated structural steel • 200 x 55 mm corrugation profile • 1.2 m plate lengths • 66 rings in total with five plates per ring (circumference) • 3.97 m inside tunnel span • 3.38 m inside rise • decline slope angle: 16.5 degrees • 18.83 m maximum height cover.

INSID E M INING 1 1 /1 2 | 2013

COVER STORY

Limited (AIL) - a world leader in developing innovative engineered solutions in structural plate, MSE wall systems and prefabricated bridges. “The structures, fully imported from AIL, are quick and cheap to assemble and install, and are very efficient compared to conventional concrete tunnel structures, which are usually very heavily reinforced because of negative soil arching (i.e. the phenomenon where rigid structures buried in soil attract and carry substantially more load than the soil overburden). Soil structure interaction is a key focus area of SSIS and is part of the reason we are able to fulfil our goal in meeting quick deadlines at minimal cost, thereby delivering clients with true value engineering,” Webb outlines. While the overall project can be described as a relatively seamless process, SSIS and G4 Civils had to contend with a few challenges. “Unlike a traditional decline, which ranges at a dipping angle of between 7 and 10 degrees, and a traditional chairlift decline, which dips at about 12 degrees, the BRPM north shaft chairlift decline is at an

ABOVE The tunnel took three days to install BELOW The design of the box cut is critical to the overall project as it must support and accommodate the tunnel in terms of angle, length and support

ABOUT BRPM RB Plat holds a 67% interest in BRPM, with partner Anglo American Platinum holding the rest. The mine has a 4E resource base of 72.4 Moz (57.6 Moz, measured and indicated). It is predominantly a Merenksy reef mine, supplemented by additional UG2 ounces. Operational since 1999, it still has decades of life remaining. It has full mining and concentrating infrastructure on-site, with a 200 000 tpm nameplate capacity.

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OTHER SSIS AND G4 CIVILS PROJECTS

extremely deep 16.5-degree angle. The reason for this can be attributed to unstable ground conditions and the need to reach more stable bedrock material as well as the requirement to align the tunnel with the underground workings,” SSIS engineer Frikkie Rautenbach points out. The final project element, prior to the installation of the chairlift, is backfilling the box cut – a major engineering feat in its own right. “At 80 m long with a 23 m highwall, the box cut shape was designed to accommodate the tunnel’s shape, ensuring it provides support once filled, especially with the added steepness pressure. And filling it was also performed according to a specific design plan. A mixture of the removed box cut soil and cement will be placed in equal amounts at the same time on both sides of the tunnel to ensure

SSIS has completed projects similar in nature to the BRPM tunnel. Both larger in terms of tunnel dimensions and length, Sasol Mining’s two new mines Thubelisha and Impumelelo both access underground via an SSIS pre-assembled tunnel. The company’s Shondoni brownfields expansion project also includes an SSIS tunnel. G4 Civils boasts a similarly impressive work portfolio. The company is currently under way with numerous civils, earthworks and construction mining-related projects for Xstrata South Africa (trading as Glencore), Impala Platinum, Modikwa Platinum and Shanduka.

it does not roll or move out of position,” Badenhorst outlines. Completed in November, Van Wyk says the project has achieved excellent safety results and remains well within budget and time frame, “thanks to solid working relationships between parties and a common goal”. Installation of the chairlift will proceed on completion of development. It will connect to the mine’s 5 Level and directly to an underground chairlift. “We are extremely proud of this project and what we have achieved for our client. It also leads the way forward in working together on future projects to deliver turnkey solutions,” Webb and Badenhorst conclude.

CRUSHING AFRICA’S ROCK

HOT SEAT

LEHATING MINING

Developing a manganese It is no secret that junior mining companies are struggling to gain investor confidence in a cash constrained economy. South African manganese explorer and developer Lehating Mining is bucking the trend, attracting interest from an array of possible financial partners, CEO Charles Sambo tells Laura Cornish.

ITUATED IN THE Northern Cape’s Kalahari Basin, Lehating Mining’s claim to fame is its 98 ha deposit, which contains high grade manganese (˃44%). It is synonymous with the characteristics of the highgrade Wessels-type manganese ore mined at Assmang’s N’Chwaning and Samancor Manganese’s (owned by BHP Billiton and Anglo American) Wessels mines, but is not a contiguous extension of those deposits. Wessels-type manganese ore is the industry’s recognised manganese-high grade benchmark,” Sambo explains. For a junior, the company is making remarkable progress in moving its project up the value curve. The company has already completed a two-phase drill

In October 2012, Lehating Mining submitted its mining right application. Both the environmental impact assessment and environmental management programmes were also lodged in August 2013. “We realistically expect the mining right to be awarded during 2014. We have ticked all the boxes in terms of regulatory approvals and do not foresee any hiccups. We want to have an operational mine by 2017. We still remain the only new entrant bringing a high-grade project on stream within the next few years.” As far as Sambo is concerned, 2017 is perfect timing. “Reports are indicating that the world economy is recovering, in turn creating an increase in demand for steel, which is the main industrial use of manganese. Our production start-up will coincide perfectly with this demand. The timing of the project is working hugely to our advantage. As a junior, this is where we want to be,” he states. One of the biggest challenges facing new and expanded manganese and iron ore deposits in the region is export rail allocation. Lehating Mining has, however, already pre-qualified for a 500 000 tpa Transnet rail allocation. “While we have no doubt of Transnet’s commitment to increasing its capacity, we have been approached for 100% of our product from the Charles Sambo, local market and will consider this alternative option if necessary. The Lehating Mining CEO 2 mm fines (equating to 10% of total production) will most likely be disprogramme, released a Competent Pertributed locally anyway,” Sambo indicates. son’s Report and towards the middle of “Discussions with Eskom for power are last year completed its bankable feasibilalso already under way,” Sambo continues. ity study. “The results were positive and He says one of the company’s challenges we are taking the next steps forward,” is the scarce labour pool in the Northern Sambo notes. Cape. The mine will need to employ about

“We remain the only new entrant bringing a high-grade project on stream within the next few years.”

10 I NS IDE M IN IN G 1 1 / 1 2 | 2 0 1 3

350 people (mainly contractors) who will need to be sourced from the Kuruman area. “The mitigation factor is that the Northern Cape is now the fastest growing economic region in South Africa due to the number of mining projects and is attracting more people seeking employment.”

The operational plan The mining and processing plan is to produce about 50 000 tpm of saleable product over a 14-year period. The ore body is shallow, extending no deeper than 320 m. The

HOT SEAT

masterpiece RIGHT Evaluating core samples on-site BELOW Lehating Mining has pre-qualified for a 500 000 tpa Transnet rail allocation

bankable feasibility study indicates the most viable mining extraction method will be via 260 m deep twin vertical shafts. It will be a fully mechanised board and pillar mine, which accommodates the thick ore body reefs (average 6.8 m). There is no further processing, after crushing and screening, because the grade is so high. “The mine will deliver three different product sizes through a simple crushing and screening circuit; 80% of this will be a -75 mm lumpy product.”

The financing plan What could be considered most critical to the project at this stage is funding – the final step needed to move from exploration into pre-construction. Sambo says

the company is already engaging with local and international banks. “There is solid support to provide debt funding for

HOW LEHATING WAS FORMED Lehating Mining is one of South Africa’s junior BEE mining companies born from 2004’s Mineral and Petroleum Resources Development Act. Named after the farm Lehating, the six-year-old company was formed when a group of eight professional engineers, metallurgists and geologists acquired the prospecting rights to the property after the former owner, BHP Billiton, relinquished its old order rights.

our project. Our current shareholders will also continue to provide equity finance.” Projected capital cost to take the project through to production is US$150 million (R1.49 billion) and debt funding based on indicative term sheets will be between 50 to 60% of this.” Metals financier, investor, trader and marketer Traxys, which will be responsible for marketing and distributing the product, recently increased its shareholding in Lehating Mining from 18.1 to 39.7%. “We have also started looking for possible strategic partners to develop the project. The strategy going forward is to embark on a roadshow in the first quarter of 2014, aimed at bringing stakeholder partners/ investors on board.” Once cash is secured, Lehating will enter its development phase that should take approximately three years to reach production.

The bigger picture The Lehating ore body extends beyond the company’s farm boundaries, with different portions belonging to other mining companies. “We remain in discussions with them to look at methods of consolidating the property into a single asset,” Sambo notes. The result of consolidating these ore bodies would probably double Lehating mine’s lifespan. Expanding rail capacity would also then have to be considered.

INSID E M INING 1 1 /1 2 | 2013 11

FROM THE FOSSIL FUEL FOUNDATION

SYNTHESIS OF CARBON NANOTUBES USING NEW TECHNOLOGY

Major new high-value The use of coal as a carbon source for the production of carbon nanotubes (CNTs) using an innovative new approach necessitated an interdisciplinary study, which showed that they are likely to have invaluable, innumerable and longterm applications in Southern Africa, Africa and rest of the world. By Kapil Moothi

HE STUDY WAS CONDUCTED under the supervision of Prof Sunny Iyuke and Prof Rosemary Falcon from the University of the Witwatersrand, Dr Meyya Meyyappan from the Centre for Nanotechnology at NASA and Dr Willem Augustyn, who is affiliated with the South African Nuclear Energy Corporation, for my PhD research work. The field dealing with structures of carbon having at least a single dimension with the size of a billionth of a metre is called carbon nanotechnology. The discovery of the fullerene molecule, referred to as a “buckyball”, in the 1980s and the

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characterisation of CNTs with a transmission electron microscope (TEM) in the early 1990s stimulated interest in this field of research1. A CNT is a one-atom-thick graphene sheet that is seamlessly wrapped around into a cylindrical shape, with a diameter in the nanometre range (hence the name nanotube), although they can be many millimetres in length1, 2. A single-walled carbon nanotube is a crystalline, one-atom-thick sheet of graphite rolled up into a hollow cylinder with a diameter varying from 0.4 to 2 nm and a length in the order of microns. CNTs consisting of a number of concentric graphitic layers with diameters varying from 10 to 100 nm, and

a length greater than 10 μm are termed multi-walled carbon nanotubes. CNTs have arisen as a dynamic field of study due to their unique properties, which make them useful in applications such as hydrogen storage, carbon dioxide sequestration, field emitters, flat panel displays, data storage, capacitors, fuel cells, composites for aerospace applications or body armour and space suits, catalyst supports, drug delivery and many other fields2. The myriad applications of CNTs in various fields since their discovery are of great importance as it is clear that novel technologies for their use will emerge in the future2, 3. It is also expected that more applications of CNTs will

FROM THE FOSSIL FUEL FOUNDATION

use for coal be found when some of their known (and unknown) unique properties are explored. Results by Maphutha4 et al (2013), recently published in Nature, show great promise in the use of a CNT-infused polysulfone membrane (with polyvinyl alcohol layer) for the treatment of oil-containing wastewater. This novel membrane could aid in solving the acid mine drainage (AMD) problem that is present in South Africa. The three main techniques2, 3 used for the synthesis of CNTs are arc discharge, laser ablation and chemical vapour deposition (CVD). The application of the CVD process in using direct coal-derived hydrocarbon products is a new and exciting possibility for CNT synthesis3. Coal is inexpensive and widely available in comparison to the most widely used solid carbon precursor, graphite and high-purity hydrocarbon gas sources. CNTs produced using CVD5 are considered to be of high quality and this technique can be scaled up to synthesise large quantities of CNTs in a continuous operating mode. Although there are several production methods and carbon sources to synthesise various kinds of CNTs and carbon nanomaterials, large quantities of high-purity and high-quality CNTs are still too expensive for the realisation of industrial applications. The market for CNTs, carbon nanofibers, fullerenes and graphene has been growing rapidly in recent years3. As large quantities of various types of CNTs are needed in market-driven applications such as composites, catalysis, semiconductors, electronics, etc., the prohibitive costs could drastically diminish the benefits of using CNTs in these applications. Hence, a detailed study of the in situ synthesis conditions (e.g. temperature, gas mixture composition) for the production of CNTs by CVD using direct coal-derived hydrocarbon products is currently being undertaken. The project involves the gasification of (or pyrolysis of) South African coal, separating the light organic gases from the other products and transforming the light carbon-containing gases into CNTs

The technical experience that South Africa has in gasification and pyrolysis of coal has allowed it to currently circumnavigate this disadvantage. The development of the new technique mentioned in this article, if economically viable, could lead to a new industry generating coal-derived high-value products in the form of CNTs. The produced CNTs are likely to have invaluable, innumerable and long-term applications in Southern Africa, Africa and rest of the world6.

The development of the new technique could lead to a new industry generating coal-derived high-value products in the form of CNTs using a CVD reactor. Successful utilisation of CNTs in various applications is strongly dependent on the development of a simple, efficient and an inexpensive technology for mass production and coal has the potential to be the inexpensive source of carbon in this process3. South Africa, with its large reserves of coal, low production costs and prices, and sophisticated transport handling systems, has become a prime participant in the international marketing of coal. It is one of the few areas capable of producing and exporting the large volumes of coal needed in the metallurgical and thermal markets6. In addition, South Africa possesses 10% of the world’s coal reserves, even though the ROM coal quality is lower in grade and quality than those in Europe and North America6.

References:

[1] Iijima S. Helical microtubules of graphitic carbon. Nature 1991; 354: 56-58. [2] Meyyappan M, editor. Carbon Nanotubes: Science and Applications. Boca Raton, FL: CRC Press; 2004. [3] Moothi, K, Iyuke, SE, Meyyappan, M, Falcon, R. Coal as a carbon source for carbon nanotube synthesis. Carbon 2012; 50: 2679-2690. [4] Maphutha, S, Moothi, K, Meyyappan, M, Iyuke, SE. A carbon nanotube-infused polysulfone membrane with polyvinyl alcohol layer for treating oil-containing waste water. Nature Scientific Reports 2013; 3(1509): 1-6. [5] Yah, CS, Simate, GS, Moothi, K, Maphutha, KS, Iyuke, SE. Synthesis of large carbon nanotubes from ferrocene: chemical vapour deposition technique. Trends in Applied Sciences Research 2011; 6(11): 1270-1279. [6] Moothi, K, Falcon, R, Meyyappan, M, Augustyn, WG, Iyuke, SE. Carbon nanotubes and the role of South African coal as a viable carbon source in their synthesis. South African Institute of Mining and Metallurgy 2013; (Accepted).

KAPIL MOOTHI IS A MEMBER OF THE FOSSIL FUEL FOUNDATION Moothi is a PhD candidate in the School of Chemical and Metallurgical Engineering at the University of the Witwatersrand, where he completed his BSc (Eng) and MSc (Eng) studies. As a PhD candidate, he has played an active role in the mentoring of first-year chemical engineering students. Moothi’s research experience lie in coal processing for carbon nanotechnology applications, carbon dioxide breakdown, methane decomposition, dry reforming and catalysis. In 2012, he participated in the first Falling Walls Lab Johannesburg, which provided a platform to share the innovative ideas involved in his PhD research work that are relevant to society, environment and the world. In August this year, he was a presenting delegate at the 9th World Congress of Chemical Engineering (incorporating the 15th Asian Pacific Confederation of Chemical Engineering Congress), held in Seoul, South Korea.

INSID E M INING 1 1 /1 2 | 2013 13

IN THE SPOTLIGHT

LOW- GRADE IRON ORE

Breakthrough density distribution analysis technique Kumba Iron Ore’s Sishen mine in the Northern Cape may be 66 years old, but it is upholding its status as the company’s flagship operation thanks to investment in research and development aimed at improving efficiencies as lower grade areas materialise, writes Laura Cornish.

HILE THE MAJORITY of traditional processing technologies still cater to highgrade materials, the reality is that these resources deplete as a mine ages. Sishen is a prime example. It may still have more than 20 years of life remaining, but is tapping into low-grade areas as the pit dips and deepens. The situation is seeing Kumba Iron Ore invest in numerous asset optimisation pilot projects and test work aimed at improving operational efficiencies and enhancing revenue. One such initiative is providing support to a research project directed at developing an alternative density separation analysis technique for the characterisation of lowgrade iron ores. “We have developed an industry first: groundbreaking technology analysing density distribution by applying electronics that can evaluate single particles,” says Shamudulu Shamaila, head of this project research team at Anglo American’s Technical Solutions Research business. BELOW Sishen Iron ore mine Photographer: Philip Mostert

14 I NS IDE M IN IN G 1 1 / 1 2 | 2 0 1 3

“Technical Solutions provides research and operational support to all Anglo American companies, business units, projects and subdivisions,” says Sandip Naik, Bulk Commodity manager at Technical Solutions. The business is involved in Anglo American’s technology development strategy, aiming to advance technology across the mining value chain to achieve the vision for mining in the future, namely zero harm and operationally cost effective; automated; and more carbon neutral, water and energy efficient. Certain bulk commodities, such as iron ore and coal, utilise the difference in density between the value and the waste material as part of a value-add process before being sent to market. Understanding the density distribution in these materials is therefore critical

to both process design for new projects and process control in optimising existing operations. Traditional density distribution analysis techniques have limitations in determining materials of high densities (above 4g/cc). As the industry increasingly processes lower grade haematite ore, determining the distribution of density in a sample at density values greater than 4g/cc has become necessary. “The breakthrough factor is that this technology succeeds in automated analysis of sample sizes ranging from 1 to 25 mm on a particulate level. This has previously not been readily achievable,” Shamaila proclaims. Traditional ‘sink and float’ density distribution analysis has remained pegged at a ceiling for some time and, in certain

IN THE SPOTLIGHT

an option to sort the material into several density ranges, facilitating faster processing and repeatability of results. The instrument’s software retains detailed information of each applications, it is also associated with the use of tetrabromoethane, particle and makes it possible for process engineers to draw this ina chemical classified as hazardous to humans and the environment. formation into various statistical models and analyses. Although the handling of such chemicals is governed by strict safeThe development of this monitor reflects an international trend ty guidelines, Anglo American’s towards increased automation in the mining commitment to safety is driven industry. It is poised to add immense future by a desire to eliminate hazardous value to the industry, presenting the oppor“We have developed chemicals wherever possible. “This to automate the computation of washgroundbreaking technology tunity technique has eliminated the use ability curves at a reduced price, compared analysing density of the toxic chemicals traditionally to the traditional sink and float method. In used in this type of analysis,” Shafact, XRT WAMON analysis is likely to come distribution by applying maila notes. in at about half of the cost of existing manual electronics that can “Our research team has effecparticulate-based analysis methods. Potentively created an alternative techtial savings on cost of chemicals and better evaluate single particles” nology that is configured in such a process control are therefore estimated to be way that in the longer-term future in the millions of rand. it could potentially run online within a processing plant, providing real-time process analysis and allowing process engineers to respond far more timeously in making adjustments to the system. Although it is calibrated for haematite at present, it will become possible to calibrate it for other material types, such as coal and diamonds,” he continues. Shamaila says the research team is already liaising and working with Kumba process engineers to ensure “that we can match their needs to our capabilities”. Bulk Handling is our strength. The Kumba Iron Ore-sponsored research project started in 2010 as Vibration technology is our paradigm a collaboration between Kumba Iron Ore, Anglo American’s research department and external instrumentation expert J&C Bachmann, Scalping Screens | Vibrating Feeders a German company with expertise in radiometric material analysis. Extro Vib-Systems | Classifying Screens Vibrating Grizzly Feeders / Screens “The majority of the 15 people involved in the project, however, were Multi-slope (“Banana”) Screens South African,” Shamaila notes. Dewatering Screens | Straboflex The researchers were tasked with developing an alternative methScreens |Oscilla Screens Fine Screening od to measure particle density, as well as the physical separation and classification of different particles according to their measured denRefurbishments as well as the supply of sities. To achieve this, optical imaging, laser and X-ray transmission OEM spares (incl. exciters, unbalanced motors, electromagnetic vibrators, shaft (XRT) were harnessed to measure particle volumes and densities. drives and other drive components). These integrated tools are housed in an analytical unit called the XRT Washability Monitor (WAMON). Part of the JÖST Group www.jvtvibration.co.za Between 2010 and 2012, modifications were made to the protoTel no: 011 397 1087 type laboratory test instrument, and analytical application comEmail: info@jvtvibration.co.za menced with haematite ore research in 2013. The XRT WAMON comprises four sections: feed, optical, XRT and sorting. The material sample is presented to the optical section via a conveyor belt, during which images are captured through line scan cameras. The material is then exposed to X-ray, similar to medical X-ray technology. At this point the information gathered from the optical and X-ray sections is merged through a computer processing unit, making it possible to determine the density of each particle being scanned. The system retains the ‘address’ of each particle on the belt on a continuous basis, and in the robotic sorting section there is LEFT The XRT WAMON sorting circuit MIDDLE The XRT WAMON feed circuit RIGHT XRT WAMON

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IN THE SPOTLIGHT

BENTLEY PARK

Safety leaders of today Murray & Roberts Cementation’s Bentley Park training academy is playing a fundamental role in the mining sector, contributing towards the industry’s uncompromising demand for safety. Ensuring that no worker operates without fully understanding operational risks and the required responsibility to avoid them is its non-negotiable priority, writes Laura Cornish.

STABLISHED IN 2005, the academy is recognised for its contribution to uplifting and promoting safety in the mining sector through training and equipping workers to understand their work environment and the machines they operate. The facility is enormous and offers almost every mining-related training service available, including computer learning and education to on-site practical experience in mock-up environments. Between 40 and 60 learners, from artisans through to supervisors, move through the facility each week, trained by 52 fully qualified staff members. The Cartetonville-based facility ensures that it stays up to date with the latest mining trends, techniques, methodologies and processes and updates its training and solutions accordingly. “Using modern equipment and trend-changing practices, such as mechanised mining and new shaft sinking approaches, we ensure that every machine operator and miner is well equipped to handle new machines and techniques and solve associated problems,” says Tony Pretorius, Murray & Roberts Cementation (Bentley Park) risk manager. “At Murray & Roberts, we believe technical skills training is the grounding for a safe and successful mining career and the upliftment of a safe mining environment, which ultimately is driven by risk. We teach people to perform a skill proficiently, but most importantly, with the aim of ensuring it is executed safely. Through our systems and processes, we give people the means to work safely and through education, training and development, allowing the employer to hold the employee to task to perform accordingly,” he says. Bentley Park received its first Mining Qualifications Authority (MQA) accreditation in 2008 and was recertified and accredited in April 2011. “We face an MQA accreditation audit in 2014 and are confident of full approval,” Pretorius outlines. “I also believe we are the only training centre with ISO Trainees learn in an underground mockup environment

16 I NS IDE M IN IN G 1 1 / 1 2 | 2 0 1 3

IN THE SPOTLIGHT

and tomorrow certification across all management systems, including ISO 9 001: 2008 and 14 001.” Bentley Park has an MQA safety programme and also subscribes to the global industry risk management programme that was initially developed in conjunction with the University of Queensland and Anglo American. While Bentley Park caters to Murray & Roberts’ (Group) 6 000 employees, Pretorius believes it has the potential to benefit the larger mining industry if it caters to all companies looking to use the facility for its training services. “For now, we extend our services to the mining companies that we work with on projects, which results in a standardisation of work and safety practices across a project.”

Training platforms Pretorius admits that the company’s greatest challenge, although not one that can’t be overcome, is poor literacy levels in South Africa. “We have many foreigners and historically disadvantaged South Africans who never had formal schooling. In addition to solving this by recruiting mostly Grade 12s for novice positions, we also cater to the most common South African languages from English and Afrikaans to Xhosa, Zulu, Sotho and Tsonga, to ensure the best possible knowledge transfer,” Pretorius explains. In line with its capability to service a high volume of learners, the Bentley Park facility has been designed to manage this

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cost effectively. ggain knowledge and mines has become more onerous, more m In addition to its more importantly, complex, contradicting and often difficult to implement within the time e u n d e r s t a n d i n g .” 65-computer conframes specified T tingency for semiThe academy fur– Charlaine Baartjes, MD tther includes 15 skilled e-learning, at EcoPartners le Pretorious says its lecture rooms and tthe recently introthin client principal works particularly well. In essence, a thin duced simulator building, implemented client enables 10 monitors to work from in mid-March, enabling the transfer of a single computer, knowledge and understanding into basic which drives computskills application. er operational costs The completion of ‘room-bound’ traindown substantially. ing moves the learners on to real working Bentley Park’s TMM experience through mock-up programmes e-learning venue for conventional mining, shaft sinking houses 10 thin and mining services. “We are coming out clients or 100 of a conventional shaft sinking environmonitors. Its ment into a refined, safer way of sinking

“For now, we extend our services to the mining companies that we work with on projects, which results in a standardisation of work and safety practices across a project.” Tony Pretorius, Murray & Roberts Cementation (Bentley Park) risk manager

skilled e-learning venue houses another 30 (300 monitors). Its visual-based training centre seats another 10 learners and includes both the Vienna international test system as well as the locally adapted Dover system. “It is essential to offer both e-learning and visual training, in order to Underground operator simulation training under way

shafts. Bentley Park has already adopted a training process, in conjunction with our international sister companies, to teach learners methodologies to sink shafts more safely,” explains Pretorius. In line with its goal to remain abreast of all new mining techniques further, Bentley Park has expanded its underground mining training to incorporate mechanised mining techniques, in addition to

PRODUCTS AND SERVICES OFFERED CENTRALLY TO MURRAY & ROBERTS CEMENTATION EMPLOYEES • conventional mining portfolio • trackless mechanised mining • basic engineering, including: – electrohydraulic – engineering assistants – torch cutting – angle grinding – basic rigging – fire extinguisher operation – basic hand tools • mining services, including: – diamond drilling operators and attendants – drop raise operators and assistants – high pressure injection operators and assistants – surface grout plant operators and assistants – underground grout operators and assistants • shaft sinking • supervisory development, including: – advanced TMM miner – trade/blasting certificate refresher – day in the life of a supervisor • safety, health, environment and quality training, including: – MQA Safety Rep – MR1, 2 & 3 SHE Risk Management – Basic Risk Assessment – Incident investigation – Working at Heights – HWSETA Level 2 & 3 Qualifications • course administration • accommodation and feeding • data capturing.

conventional mining training. “Most of the clients we engage with are considering mechanised mining methodologies.” The academy offers a variety of different machines, used in industry, supplied by major industry players. Supervisor training is as important to a fully functional development project. “While supervisors do not operate machinery, at Bentley Park we believe it is important that they have a basic understanding of the mining equipment in use as well as a typical day in the life of an operator. We further provide them with rock bit training, enabling them to identify and recognise wear and tear, especially if it is a result of incorrect drilling procedures.”

Outsourced qualifications/certificates of competency Bentley Park works with numerous different institutes to provide training in areas

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IN THE SPOTLIGHT

EMBEDDING A SAFETY CULTURE AND A HOME Bentley Park can sleep up to 407 employees at any given time. It has two kitchens serving three meals a day. Fedics Site Services is the contractor providing all meals to all learners. It sleeps 359 semi-skilled men on campus and 24 semi-skilled ladies, 18 skilled men and 6 skilled ladies.

that its internal capabilities do not meet. These include Anglo American, AngloGold Ashanti, Manitou, Sasol, Gold Fields’ Academy, Sandvik (Trans4Mine), AARD Mining Equipment and the University of Pretoria.

In the real world “Our policy is not to take our learners and ‘throw’ them back to our clients once the programme is complete,” says Pretorius. All training portfolios are available on a network and records of every programme completed. An outline of how each employee is performing during training and once completed is available to the client for referral. The documentation accurately

Bentley Park has implemented new shaft sinking practices

reflects the learning that took place at the academy and how their competency levels have developed. “This provides our clients with peace of mind and confidence

in the workforce and the comfort to develop working relationships with us, how we operate and what value we add. The goal is to ensure that workers do not require micro-management when they return to work.”

INSID E M INING 1 1 /1 2 | 2013 19

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JUNIOR MINING

GEOLOGICAL GENIUS

PPM’s greatest challenge

Most platinum miners are struggling in the midst of weak PGM prices, depleting shallow resources and strike-related nosediving profits, but junior company Platmin has had to grapple with its own unusual set of challenges. In true ‘junior style’, however, it has overcome adversity and is now delivering great rewards, writes Laura Cornish. 20 I NS IDE M IN IN G 1 1 / 1 2 | 2 0 1 3

LATMIN HAS WALKED a long and arduous road since production start-up (in 2008) at its Bushveld Complex, Western Limbbased PGM operation, Pilanesberg Platinum Mine (PPM). Platmin COO Casper Badenhorst admits that production in the first year was challenging, but adds that the mine’s steadfast commitment to delivering a profitable operation was and remains non-negotiable. And it is this attitude that has seen the PPM team implement a mining methodology previously unseen in the platinum industry to accommodate its complex geological structure, which is attributed as the start of turnaround results for the operation. Based on the successes starting to emerge at PPM, five years since its start, work is also under way to expand Platmin’s single operation portfolio and bring on-stream the contiguous property, Sedibelo. The introduction of the new mine represents the company’s status elevation from junior to mid-tier miner, moving the company up the production curve and providing it with greater revenue-producing prospects. And its potential extends even further: Platmin is the owner of 15 Moz of resources on the Eastern

JUNIOR MINING

its greatest success

LEFT PPM mines the UG2 reef and a platinum-bearing silicate reef ABOVE Aerial view of the PPM process plant TOP RIGHT The PPM mine is opencast and comprises a single pit, 3 x 1.3 km BELOW RIGHT Outotec flotation cells

Limb and another contiguous 44 Moz on the Western Limb.

platinum-rich Merensky reef with which the industry associates PGM mines. In addition to a 1 m thick UG2 reef, we mine the platinum-bearing silicate reef, comprising the 5 m thick upper and lower pseudo reefs at a grade of about 1.63 g/t. Our Merensky reef is only 10 cm wide, making it uneconomic to mine,” Badenhorst explains. Finding a successful mining and processing solution and catering to the ore body’s

geology has been PPM’s greatest tribulation, but also its greatest success. “When we started mining here, we started with a single mining contractor that met our methodology requirement to mine selectively using the traditional drill, blast and load. By 2010, however, we had realised that the faulting in the area was more severe than anticipated and as a result we were not meeting our stripping ratio targets, which on average are

PPM’s remarkable turnaround PPM is probably one of the only PGM mines that does not neighbour a platinum major, making it relatively isolated by comparison with its peers. It is situated far north of Sun City, but still falls within the Pilanesberg district. The mine is an opencast operation comprising a single pit (3 x 1.3 km) divided into north, south and central sections. While currently mining at a depth of 60 m, it will extend to about 180 m. It has an 11-year lifespan remaining and employs 500 people directly and another 1 500 through contractors. The mine’s geological ore body structure is also unique to the region and was the contributing factor towards its start-up problems. “We do not have the traditional

INSID E M INING 1 1 /1 2 | 2013 21

JUNIOR MINING

ABOVE Milling circuit for silicate package RIGHT Interior view of flotation cell

about 12:1. Attempts to increase volume were also unsuccessful,” Badenhorst outlines. In true junior style, PPM devised a new mining methodology that has resulted in a complete turnaround. At the end of 2011, two additional reefing contractors were introduced to the mine, leaving the original contractor to focus on waste mining only. Three different drilling contractors were also brought in. “We started meeting our stripping ratio targets, which will reduce over time, removing all the necessary waste, the reef followed and the plant subsequently filled. We are bulk blasting 15 m benches, but still loading selectively.”

NA-SERA MINING SERVICES

In July 2012, the plant operator contract was also terminated. PPM’s direct involvement in operating the process plant (incorporating a silicate milling circuit and a UG2 milling circuit) has subsequently resulted in successful maintenance procedures and high availabilities. With the mining process working smoothly, the plant has started reaching capacity and today is on occasion exceeding it. “We have been processing as much as 75 000 tpm on the UG2 circuit (designed for 65 000 tpm) and 250 000 tpm on the silicate circuit (designed for 220 000 tpm).” There is also potential to increase the plant’s capacity. Platmin is currently investigating a new sorting technology capable of separating waste from reef in the silicate plant, thereby delivering a silicate package upgrade. Although there is significant chrome in the UG2 reef, PPM is achieving its target of delivering a concentrate to its off-take agreement smelters with less than 1% chrome. Chrome extraction research and development, along with tailings retreatment, is under way, but remains a non-core business focus. Despite PPM’s mining challenges, Badenhorst says it is the potential that lies around the PPM mining licence that holds value for stakeholders. At 180 m depth, the ore body is not as deep as conventional platinum underground mines. “Even our future underground mines won’t be as deep,” he adds.

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Situated in an arid region, PPM is slightly water constrained but has enough to run the plant and operate the mine. “We cannot afford to waste water; however, making recycling (50%) an important process element.” The construction and installation of an extra Magalies Water pipeline, which is due to start shortly, will give us enough water for our upcoming projects and community commitment. The operation’s water allocation is currently 4.5 Mℓ/d of unused water, also accessed via a pipeline. This capacity will increase to 9 Mℓ/d with the new pipeline. It should take about 18 months to complete the pipeline, which will supply sufficient water to PPM and Sedibelo. The company will also introduce a water savin saving initiative to the ar area. “We were iniMines can use their understanding of the tia going to backtially environmental legal requirements as a l the pit at the end fill competitive advantage. An unintended of its life, which is a consequence of all the environmental requirements is that the co costly activity. Our barrier to entry has risen pl plan, however, is to significantly – Charlaine pa partially backfill the Baartjes, MD at EcoPartners pi and allow for a pit

22 INSID E M INING 1 1 /1 2 | 2 0 1 3

JUNIOR MINING

dam to develop by letting it accumulate rainwater, which currently pools after rain and then evaporates. It could be used for irrigation, animal and community consumption, etc.” PPM currently complies with all legislation relevant to its mining right. The company is also driving local employment heavily, in a concerted effort to contribute to regional upliftment. “Because we know what projects are coming on line in the near future, it is our responsibility to start training people for some of those roles now, and we are doing so. And, contradictory to popular belief, there are valuable skills.”

Sedibelo – the start of Platmin’s future Sedibelo is situated 3 km to the east of PPM and will be similar in size. The geological structure is also the same. “Because we already have the mining licence, our intention to start mining and producing reef towards the end of 2014 is not unrealistic. We have started putting up fencing and talking to the land users and owners, mostly cattle farmers,” Badenhorst notes.

“We do not have traditional platinumrich Merensky reef with which the industry associates PGM mines.” Casper Badenhorst, Platmin COO

Taking the possible incorporation of the new sorting technology and mining output in account, the combined life of mine between both PPM and Sedibelo is about 12 years, with a significant increase in metal output. With the learning curve at PPM completed, bringing this project online should be smooth and relatively hassle free. “We will build a box cut and start mining the reef material immediately. Owner-mining versus contractor-mining will also be evaluated. No plant expansion is required either; the plant was originally designed to accommodate Sedibelo’s capacity, with or without the incorporation of the new sorting technology. Sedibelo also has underground resources, which will be accessed via a decline system. Development will start within the next two years to reach steady state production at 2020. Its depth will be no deeper than about 600 m – still low level mining by comparison with deepening platinum mines. With water and power (66 MvA) already allocated, Sedibelo’s prospects appear positive. The underground mining operation will extend the LOM significantly beyond the 12 years.

INSID E M INING 1 1 /1 2 | 2013 23

JUNIOR MINING

WESCOAL HOLDINGS

Making the most of Labour unrest and the declining rand value may make for challenging business in the mining sector, but Wescoal’s expansion in the coal market is proving that successful opportunities are still available to producers, writes Vicky Sidler. ABOVE Plant at Intibane

ESCOAL IS GROWING and looking for more opportunities all the time,” says André Boje, Wescoal CEO, commenting on the recent acquisition of MacPhail Distributors, a coal distribution company, for R79 million. Adding MacPhail to Wescoal’s portfolio is a strategic move to “lower costs and increase visibility and presence in the marketplace”.

Rooted in coal trading Increased competition from primary coal suppliers has placed the coal trading

marketing under pressure, reducing volumes and pressure on margins. The acquisition of MacPhail, however, “will enable Wescoal to attain the critical mass required to negotiate and overcome challenges in the coal trading environment,” says Boje. Coal trading is nothing new to Wescoal, which has been successfully supplying coal to the industry across South Africa and neighbouring countries since 2005. Its coal supply business has roots in Chandler Coal, its coal trading arm, which has more than 80 years’ operational experience. A thorough knowledge of the workings of

Most of the coal from Wescoal’s mining operations will be delivered to Eskom, according to a R700 million deal signed in 2012 to supply 3.2 Mt of coal per annum

24 I NS IDE M IN IN G 1 1 / 1 2 | 2 0 1 3

BELOW The coal seams at Khanyisa are clearly visible

the coal market, together with value-added services has, positioned Chandler Coal as a leading coal supplier in South Africa. To be an effective coal merchant, an organisation requires staff with embedded knowledge of coal markets, clients with a demand for coal, a deep understanding of market influences, the ability to source the correct grade of coal to match client needs, as well as long and established relationships with mines and customers – and Chandler Coal has all these attributes.

JUNIOR MINING

every opportunity Mining well into the future Wescoal has made significant strides in the past few years with regards to expanding its coal mining business. From a single mining operation with a short lifespan (Khanyisa), the company now owns two operational mines, with a third significant asset moving into development in the near future. Today Wescoal has a total life of mine of 12 to 15 years, and this could still grow further. “The key strategic thrust of Wescoal is to be a leading junior miner with a sustainable resource base and a coal trading operation,” says Boje, and this is clearly on the right track. In the 2013 financial year, Wescoal successfully produced 1.31 Mt of coal.

Successfully expanding its operations Wescoal has flourished since 2009, when the first coal was mined and extracted from Khanyisa colliery , which is close to the Kendal power station. “We keep extending the life of mine at Khanyisa,” says Boje, pointing out that the colliery still boasts enormous potential. The life of mine is currently 12 to 18 months, with measured reserves of 1.24 Mt. Operated and managed by Wescoal, the mine has reserves of 0.82 Mt and measured resources of 1.24 Mt. With all legal permits in place, Khanyisa includes both opencast and underground mining, employing 84 people. Boje is hoping to also extend the life of mine from two to five years at Intibane colliery, which was commissioned in June this year. The mine has been approved to supply Tutuka power station and has recently delivered its first coal to Eskom. Owned, managed and operated by Wescoal, the opencast mine boasts reserves of 1.40 Mt and measured resources of 1.73 Mt. The third mine, Elandspruit colliery outside Middelburg in Mpumalanga, is not operational yet, but Boje says Wescoal is hoping to conclude all the regulatory and

e expanding well because environmenIt is the ultimate paradox that the w understand the dowe tal formalities industry’s need for clean water for various processes and power production is in m mestic market.” early next year direct conflict with the This is evident in Wesfor mining to damage these processes do c coal’s financial results, start in 2014. to sources of clean water. w which reflect an increase While it is eas(see story on page 34) o R46 million up 7.3% of ily accessible fr from the comparative fifrom the main nancial period. “In terms of production, we road, no infrastructure has been developed are also exceeding targets,” says Boje, statas yet. ing that this trend is expected to continue The Elandspruit colliery has an existing into next year. This is despite the chalmining right with a resource of over 30 Mt, lenges presented by the increasing cost all of which can be mined opencast. Wesof coal production, diesel price increases coal’s underground Vlaklaagte mine was and the mass strike action affecting the traded with Xstrata’s Elandspruit because entire country. the colliery is better suited to opencast To maintain this growth and success, mining, says Boje. “Our focus is predomiWescoal continues to keep an eye out for nantly opencast mining.” opportunities and is currently negotiating Supplying South Africa’s market with a number of majors regarding consolMost of the coal from Wescoal’s mining opidating assets in the coalfield. “The easiest erations will be delivered to Eskom, accordpart of this business is to actually mine the ing to a R700 million deal signed in 2012 coal,” Boje says. “The hardest part is to sell to supply the power utility with 3.2 Mt of it and consolidation is an ideal way to give coal per annum. “We are not really focusing junior producers the critical mass that we on exporting our coal,” Boje says. “There is need. Wescoal is perfectly placed to benefit this perception that a mine cannot make from and take advantage of any consolidamoney without exporting, but we are tion opportunities that arise.”

Opencast mining under way at Intibane

INSID E M INING 1 1 /1 2 | 2013 25

JUNIOR MINING

AQUILA RESOURCES

Believing in South Africa’s Despite a long list of promising coal projects in Australia, ASX-listed coal and ferrous metals explorer and developer Aquila Resources is investing time and money in its South African projects, Avontuur and Thabazimbi, to unlock the company’s full value potential, writes Vicky Sidler.

Drilling on the Avontuur project was recently completed

QUILA RESOURCES (Aquila) has invested more than R450 million exploring for iron ore and manganese across nine exploration tenements since coming to South Africa in 2006 and has consequently identified two major projects. The Avontuur manganese project is located adjacent to South Africa’s premier manganese producing region, the Kalahari manganese field in the Northern Cape. Situated at the northern end of Avontuur, the Gravenhage manganese deposit has revealed promising potential. Aquila’s second project, the Thabazimbi iron ore project in Limpopo, may be a long way from development, but has already shown itself to be highly attractive following the completion of a scoping study. “Aquila has been very successful in its exploration ventures in South Africa,”

26 I NS IDE M IN IN G 1 1 / 1 2 | 2 0 1 3

says Tony Poli, Aquila’s CEO. “We have two very sizeable and high-class projects with quite a bit of direct foreign investment. We are continuing to explore our project areas for additional iron ore or manganese resources.” Poli adds that his experiences in the South African mining industry have been pleasant and rewarding, saying that “one of the advantages of South Africa is that it already has installed infrastructure such as rail and port”. This is essential for both South African projects, which rely heavily on a concrete agreement with Transnet to ensure successful product export. Avontuur’s current export route is via a 1 000 km rail line to Port Elizabeth, where Transnet is expanding and upgrading the logistics corridor from around 5.5 Mtpa to about 8 Mtpa by 2017 and to 16 Mtpa by 2020. Existing rail and port infrastructure

at Thabazimbi offers optionality via Maputo in Mozambique or Richards Bay. Aquila is also working with Transnet to investigate the transport of iron ore along the upcoming Waterberg coal line corridor. “We have worked quite closely with the projects general manager at Transnet,” says Poli. “Transnet is very keen for us to commit to development alongside them. There is clearly a lot of planning going into the project from Transnet’s side.”

Avontuur manganese project Drilling was recently completed at Avontuur to upgrade resources and increase reserves. The current JORC-compliant resource is 147.8 Mt at a grade of 38.2% manganese and the reserve is 20.2 Mt at a grade of 40.12% manganese. Expenditure to date is some R150 million and development capital expenditure for an opencast mine, envisaged from the definitive feasibility study, is around US$180 million (R1.81 billion). Average estimated production is up to 1.5 Mtpa ROM, comprising 1.1 Mtpa lumps and 330 000 tpa fines, with an opportunity foreseen to beneficiate the latter locally. According to Aquila, the product has value-in-use benefits. Compared to

JUNIOR MINING

untapped potential other ores, the oxide ore has relatively low slag-forming contaminants. A number of approvals required for the development of Avontuur are already in place. Progress towards the granting of a mining right has been hampered due to an alleged overlapping prospecting right, which is currently being discussed with the Department of Mineral Resources (DMR). Aquila is, however, contesting the overlapping prospecting right dispute regarding its Avontuur manganese. Pan African Mineral Development Company, a company jointly owned by the governments of South Africa, Zambia and Zimbabwe, alleges that it is the holder of an overlapping prospecting right, hampering the application for the grant of a mining right by Aquila Resources. Aquila’s prospecting rights for the Gravenhage manganese deposit was granted five

Thabazimbi iron ore project Production in Thabazimbi is still several years away, with a mining right application only recently being lodged. The project increased its JORC-compliant resource by 19% to 80.8 Mt in December last year: 75% in the measured and indicated categories. The ore is high grade (62%+ iron) with low deleterious element levels and a high lump ratio (>65%), making it suitable for both export and domestic markets, with the opportunity to beneficiate at local steel mills. The scoping study envisages an opencast operation with a life of mine of 15+ years. With some R270 million already spent, initial capex (excluding pre-stripping) is estimated at between US$215 million and US$300 million, depending on the final logistics solution.

“We saw an opportunity in South Africa and decided to challenge ourselves with it.” Tony Poli, Aquila Resources CEO years prior to that of Pan African and almost one year after the Gravenhage mining right application was accepted by the the DMR. “It is unlikely that the matter will be resolved through further discussions,” it says. The company is considering legal action “to protect the security of its tenure on the Gravenhage manganese deposit, having advanced the project since 2006 in accordance with all relevant laws and DMR requirements.” Aquila “will take all necessary action to protect its rights, which may include an internal appeal under section 96 of the South African Mineral and Petroleum Resources Development Act (2002). This follows consultations with its BEE partner, Rakana Consolidated Mines, the DMR, the South African Minister of Mineral Resources and its South African lawyers, Webber Wentzel.

A promising future “We saw an opportunity in South Africa and decided to challenge ourselves with it,” says Poli. “There is still a lot of work to be done, but there is also clearly a lot of opportunity.” With a current market capitalisation of about R8 billion, Aquila has cash and liquid assets in excess of R5.4 billion. Poli spoke in support of the National Development Plan and National Infrastructure Plan, pointing to completed social and labour plans for both of Aquila’s South African projects. The company’s corporate social investment to date – ahead of any capital development – is more than R500 000, mostly on educational projects in its host communities. Despite the challenges faced by the mining industry in South Africa, Aquila remains optimistic about its investment. “I think the market has turned a corner, and I am very excited about the future of mining

The Veolia Water Solutions & Technologies South Africa crystalliser at Ambatovy mine, which is capable of producing up to 200 000 t of ammonium sulphate per annum, has been labelled one of the most advanced technical achievements in the field of industrial wastewater. (see article on pg 40)

in South Africa,” Poli concludes. “Right now, the world is a better place for mining companies thanks to these many potential oppotunities.”

AQUILA’S INTERNATIONAL ASSETS: West Pilbara iron ore project is a substantial iron ore export operation proposed for the Pilbara region of Western Australia. Eagle Downs hard coking coal project is an underground longwall hard coking coal mine currently under construction. It is located to the south of Moranbah in the Bowen Basin. Eagle Downs is expected to have a 47-year mine life, with a peak production rate of 5.9 Mtpa and an average of 4.5 Mtpa, from one longwall over the first 10 years of full production. Washpool hard coking coal project has advanced plans to commence the development of an open cut operation. Washpool has confirmed the viability of a 2.6 Mtpa export operation of high-quality hard coking coal over a 16-year mine life. Talwood coking coal project's concept study was completed in 2011 and a pre-feasibility study is currently under way to assess all options. Injune thermal coal project is situated across four tenements; however, only Cornwall and Bendoba have been sufficiently defined by drilling to warrant classification as a JORC resource. The project area contains a JORC resource of 826.9 Mt. Wilpeena PCI coal project's exploration has currently focused over the southern sub-blocks where coal has been intersected. The project area contains a JORC resource of 285.9 Mt. Walton PCI coal project is located adjacent to the Blackwater Rail system, which carries coal to the Port of Gladstone. The project area contains a JORC Resource of 79.2 Mt.

INSID E M INING 1 1 /1 2 | 2013 27

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ENVIRONMENTAL RESPONSIBILITY

30 0

The minefi efield around the mi m nes

Environmental law for South African mines has become more onerous, complex, contradicting and often difficult to implement within the time frames specified.

Am mbatovy’s inno nova vattive crystallise er The crystalliser at Ambatovy mine in Madagascar, designed and constructed by Veolia Water Solutions & Technologies South Africa, has received an award of distinction from one of the world’s most prestigious awards ceremonies: the Global Water Intelligence Awards.

42 2

Exploring ng new civils fronti tie ers in mine waste te

Minin ng wastewater, walking a fine line Effective water management is critical to the sustainability of companies operating in mining, and companies are required to walk a narrow line between the interests of their shareholders, the communities where they operate and the broader environment.

Rejject stream, linings laid The new brine ponds at New Denmark, Anglo American’s deep level colliery, are setting the environmental standard for reject stream water storage.

Environmental compliance has become increasingly complex and regulated over recent years and a non-negotiable requirement to mine and industry. Global consultant Golder Associates’ compliance solution lies in its transdisciplinary approach.

An energy gy-biodiversity-co oal nexus The issue of water scarcity is hugely important in South Africa, which is battling the problems of general pollution; a trade-off of water available for domestic, industrial and mining operations; and, in some provinces, acid mine drainage.

Interlock kin ing integration fo for contam minated land solutionss

Va aluing nature e is the e conservatio on key Environmentalists don’t often enter the mining industry. Jeffares & Green’s environmental manager, Magnus van Rooyen, believes that it is in the mining sector that he can best make the biggest environmental difference.

Rehab bilitating smarter, not harder Mining rehabilitation may be a necessary cost, but VBKom Rehab optimises the process to suit any budget.

Fraser Alexander Construction continues to expand its Cat scraper and allied earthmoving fleet to meet regional mining developments, recently winning the company’s largest order to date for the greenfield Husab uranium project in Namibia. INSID E M INING 1 1 /1 2 | 2013 29

ENVIRONMENTAL RESPONSIBILITY

L E G ISL L ATIO ON

The minefield around More than 120 national South African environmental acts regulate the mining industry. Environmental law for South African mines has become more onerous, complex, contradicting and often difficult to implement within the time frames specified. By Charlaine Baartjes, MD at EcoPartners HE LEGAL REQUIREMENTS that mines need to adhere to can be found at national, provincial and local level, covering more than 30 categories, dealing with at least seven authorising entities. Regular changes to the environmental legal regime are making it extremely difficult to be aware and comply with.

Strateegi St g c deci cisi s ons It is clear that the management on mines need to come up with a strategic response to the legal complexities they face. The

30 I NS IDE M IN IN G 1 1 / 1 2 | 2 0 1 3

2013 Deloitte Southern African chief financial officer (CFO) survey states: ‘From this survey, we hope to... ascertain what the underlying drivers... are shaping their behaviour and driving their strategic choices.’1 Data from this survey indicates that CFOs are concerned about the regulatory environment; 42% of CFOs place the regulatory environment as one of their top three concerns, making this the most significant concern raised by CFOs. The constantly changing regulatory environment results in substantial compliance challenges. Proving compliance is changing

into a market force of note. The market punishes non-adherence to the law, it also awards legal compliance, but the market does not consider the context against which the mines need to adhere.

Thee need d for envirron onme m ntal law w We only have one planet and we need to manage it responsibly. As part of the Constitution’s bill of rights in Chapter 2, the obligations in relation to the environment is found in Section 24 (b) where it states: Everyone has the right to have the environment protected, for the benefit of

ENVIRONMENTAL RESPONSIBILITY

mines

STRATEGIC PARTNERS

While creating a passive wetland system

present and future genUnderstandin U ing g that is fully functional and maintenance free has had limited ccompliance erations, through reasuccess, it is an option that In order to comply, sonable legislative and cannot be ignored – SRK o one must at the other measures that vvery least be aware 1. prevent pollution of the legal requirements applicable. and ecological degradation As an example, every mine will have: 2. promote conservation (1) an Environmental Management Pro3. secure ecologically sustainable developgramme Report, with its annual ment and use of natural resources while update (DMR) promoting justifiable economic and (2) a Water Use Licence, with its annual social development. review (DWA) Nobody is saying that environmental leg(3) an Environmental Impact Assessment, islation is unnecessary. What is becoming with its annual review (DEA) abundantly clear is that even the Constitu(4) a Waste Licence, with its annual review tion’s call for “reasonable legislative meas(Provincial DEA) ures” to promote justifiable economic and (5) the quantum calculations that need to social development is becoming increasbe reviewed annually (DMR). ingly difficult to defend. The reality is 77 These documents all need to be submitenvironmental national Acts have been ted to the various departments for their promulgated from 1995 to 2014. In fact, environmental legislation has doubled every 20 years since the 1940s. 1 Deloitte ‘CFO Survey 2013: Endurance the journey continues’(2013)

Before, during and after mining – if done properly, rehabilitation can return the land to its original state

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I N S I D E MI NING 1 1 /1 2 | 2 0 1 3 31

INSID E M INING 1 1 | 2013 31

ENVIRONMENTAL RESPONSIBILITY

6. legal non-compliance is considered a business risk 7. the Environmental Management Inspectors or ‘green scorpions’ are actively investigating mining areas 8. neighbours use the public participation process for their own agenda 9. reputational harm can easily be caused by any legal non-conformance.

So what to do?

FIGURE 1: The number of national laws applicable to each category that applies to mines

approval. Many more authorisations are required, but it will not apply to all mines equally.

The challeenges mines es face The challenges at the coal face for mines with regards to environmental legal requirements are considered to be the following:

32 I NS IDE M IN IN G 1 1 / 1 2 | 2 0 1 3

1. the large volume of environmental legal requirements that must be met 2. the constantly changing regulatory requirements 3. legal requirements spread over three spheres of governance (national, provincial and local) 4. conflicting environmental legal requirements 5. several authorities administer environmental legislation

Mines can use their understanding of the environmental legal requirements as a competitive advantage. An unintended consequence of all the environmental requirements is that the barrier to entry has risen significantly. Does it help our environment? The jury is still out on that. The point is, if the legal requirements that are there are effectively implemented and managed, the risk to the environment is very limited. The issue does not lie with the body making the law, but rather with the capacity to implement and regulate. In 2012, EcoPartners established that 75% of companies surveyed did not know how close they were to being closed

ENVIRONMENTAL RESPONSIBILITY

Realising possibilities...

FIGURE 2: The number of national acts per 20-year interval

down due to non-compliance. Our clients benefited from the following tools: 1. Environmental management systems like ISO 14001. This mechanism allows the mine to identify its most significant aspects, use the legal requirements (in the form of a legal register) and compile a management programme to address areas of non-conformance. 2. The Environmental Management Programme, is a Section 39 requirement of the Mineral and Petroleum Resources Development Act (MPRDA), No 28 of 2002, can be used to address all the legal requirements (in short referred to as the S39 EMPR). Updates with regards to the legal requirements are addressed through the annual updates required under Regulation 55 of the MPRDA. This tool is very effective for the environmental manager that is on top of all the changes. The changes made in the Mineral and Petroleum Resources Development Amendment Act, No 49 of 2008, will result in a change of this mechanism. 3. Some mines compile compliance checklists based on records of decision, water use licences, waste licences or legal registers, to ensure awareness and effective management. One cannot manage if they do not measure their performance against something. 4. Internal audits are considered a very powerful mechanism. Management by walking around remains the most effective means to manage potential harm that can come to the environment. The environmental practitioner that gets out to the site regularly, seen by the workforce, actively engages and makes people aware of the legal requirements has the best potential to ensure a responsibly managed mining environment.

Conclusion South African mines are currently finding themselves under compliance pressure with all the environmental legal requirements. The world has become more aware of our impact on the environment and stricter controls have been put in place to ensure responsible environmental management. In South Africa, however, since the birth of democracy, the environment has ‘gotten a very loud voice’. Inherently, this is a good thing, because we need to develop sustainably. The problem is that the legislation is fragmented, complicated, contradicting and, at best, difficult to implement.

IN S I D E MI N I N G 1 1 / 1 2 | 2 0 1 3 33

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ENVIRONMENTAL RESPONSIBILITY

W AT T ER R SCAR R CII TY

Energy-biodiversity-coal

The issue of water scarcity is hugely important in South Africa, a semi-arid country that, as a result of widespread mining activity over decades, is battling the problems of general pollution, a trade-off of water available for domestic, industrial and mining operations and, in some provinces, acid mine drainage (AMD). By Jenny Lancaster and Donald Gibson 2010 MCKINSEY ARTICLE by Guilio Boccaletti, Martin Stuchtey and Marc van Olst (Confronting South Africa’s water challenge) highlights the balancing act South Africa must play with regard to this scarce resource. They wrote: “Estimated demand for water in South Africa will reach 17.7 billion cubic metres in 2030. Actual supply will equal only 15 billion cubic metres and is severely constrained by low levels of highly seasonal rainfall (about 50% of the world average), insufficient aquifers and a dependence on water transfers between basins and from other countries (South Africa purchases nearly 25% of its total water supply from nearby Lesotho). What’s more,

34 I NS IDE M IN IN G 1 1 / 1 2 | 2 0 1 3

the effects of climate change could exacerbate the problem.” In South Africa, said the authors, the challenge will involve tough trade-offs between the competing demands of agriculture, key industrial activities, and large and growing urban centres. It is against this backdrop that South Africa’s coal industry is becoming attuned to the need for water-savvy strategies as well as a broader appreciation for the significant environmental impacts that go hand in hand with the extraction of coal. These include the alteration of landscapes, changing ecology, lowered air quality and deterioration of water resources through extraction of clean water, decant of dirty water and AMD.

Advances in mining techniques have, in some places, reduced many of the negative impacts traditionally associated with coal mining. However, it is the ultimate paradox that the industry’s need for clean water for various processes and power production is in direct conflict with the damage these processes do to sources of clean water. Exacerbating the problem is the fact that coalrich areas in South Africa are often either located in water-stressed areas, or where sensitive ecological areas such as wetlands and the associated river courses are already threatened through overutilisation or degradation. Water-rich Mpumalanga and the arid Waterberg are just two examples on either end

ENVIRONMENTAL RESPONSIBILITY

nexus of the continuum. Without proper upfront management, the development of the Waterberg Coal Corridor has the potential to become contentious as its hills function as catchment areas for the water that exists. Therefore, for projects and mines looking to establish themselves in this region, the maintenance of these ecosystems is extremely important for regional water resources and mining operations. Over and above the ecological importance of these areas – which provide not only habitats for fauna and flora that are on the International Union for Conservation of Nature’s Red Data List, but are also interlinked and thus form an important corridor for such species – there is a real business case to be made for their protection and maintenance. Why? It’s about costs and benefits; while it takes a significant amount of water to provide an energy resource, both for the acquisition of coal and for power station operation, it also takes a significant amount of energy to treat and move the water to and from these operations. Additionally, the services these habitats, also referred to as ecological infrastructure, provide would be costly to replace with man-made structures. Thus, mines are increasingly being encouraged to consider the costs of supporting the ecological infrastructure rather than destroying it. In this respect, the Department

Miners are increasingly being held of Water Affairs m methods. The water to stringent wastewater discharge ccoming out of these (DWA) is becoming regulations. This is necessitating additional ttreatment more focused on the proinvestment in wastewater treatment ccesses can be used long-term health of infrastructure to ensure both new and existing operations comply w South Africa’s water within the mining with these regulations aarea for beneficiaecosystems. While Michael Avant-Smith, ttion and processing the department has commercial director p been hamstrung by plants, dust supat Nuwater p a lack of consistpression and fire ccontrol, reused as ency in the past, it has taken notice of the AMD problem on potable water and finally released into the the reef and know it can’t afford a repeat of environment to the relevant catchment this situation. area standards. This necessitates a two-pronged approach The eMalahleni Water Treatment Plant in for water management within the coal minWitbank, some 135 km east of Johannesing industry, which focuses on minimising burg, is an example of a successful partthe amount of water abstracted and disnership between Anglo American Thermal charged into the environment for mining Coal and BHP Energy Coal South Africa to activities through reuse and recycling, and treat in excess of 130 million cubic metres managing water impacts using strong manof dirty water stored underground. The plant now supplies the municipality and community with potable water and also feeds a local water bottling company, 4Life, and meets DWA requirements, also reducing the risk of AMD. Treatment plants are a hereand-now solution, but there is also growing enthusiasm over the possibilities of passive wetland systems. These could agement controls through monitoring, mitbe harnessed to reinstate ecosystem servicigation and offsets. es or natural wetland benefits such as waWe are working with our mining clients ter purification, flood attenuation, erosion to improve their water management stratcontrol and water storage – advantages egies, aiming to reduce demand through that are usually provided by wetlands that efficiency, technology and the use of lowmay have been destroyed and/or are no er quality and recycled water. Dirty mine longer functioning at their full capacity water can then be treated and reused in due to mining activities. By fulfilling these various ways, depending on the level of functions, passive wetlands may be considtreatment; this includes active (water treatered a type of offset, especially when wetment plants) and passive (wetland system) lands in the surrounding areas are already

It is th he ulttimate paradoxx that the in ndusstry’ss need for clean water for vario ous proce esses and powerr prod ductio on is in direct conflict with th he dama age these processe es do o to so ource es of clean water

Floating wetland at a mine in South Africa

INSID E M INING 1 1 /1 2 | 2013 35

ENVIRONMENTAL RESPONSIBILITY

heavily impacted. Additionally, as wetlands are notoriously hard – and costly – to recreate, this provides an opportunity for companies to investigate offset projects while managing their water challenges. This is of significance in areas where there are many pans and seeps, such as in the Olifants River catchment in Mpumalanga. While creating a passive wetland system that is fully functional and maintenance free has had limited success, it is an option that cannot be ignored. However, until concepts like this become a reality, the challenge is to manage and limit the impact of mining on water resources and energy needs while still providing sufficient coal to meet power demands. This can be achieved by integrating water policy, planning and management within the mine planning to encourage conservation, motivate innovation and ensure sustainable use of the water resource. We see in South Africa and around the world that mining companies consistently fail to collaborate sufficiently within their regions. While a cluster of mines may share

the same underlying geology and must go through the same processes, they usually don’t work together to solve problems. But they must. The situation in Witbank necessitated successful collaboration and the Waterberg is most certainly another impending disaster if it’s not managed properly by all stakeholders.

Ultimately, the message is clear: You can’t build a power station or operate mines without having a knock-on effect on water issues, biodiversity issues and social issues. They are all linked. A holistic and integrated view is needed and that requires collaboration between NGOs, governments, companies, mines and local communities.

DONALD GIBSON IS A PARTNER AND PRINCIPAL CONSULTANT AT SRK CONSULTING IN JOHANNESBURG with 14 years’ experience in the fields of environmental and social assessments. He advises clients on the sustainability aspects of development projects in natural resources and infrastructure sectors in Africa and is facilitating Nedbank Capital’s Sustainable Business Awards. Gibson is involved in policy advisory work on sustainable development for government departments and advises companies on sustainability mainly in the transport, logistics, construction, mining, food and beverage, and petrochemicals industries. On the Faculty at the University of Pretoria’s Gordon Institute of Business Science (GIBS), he lectures on sustainability and corporate responsibility for the MBA and corporate education programmes.

JENNY LANCASTER IS A SENIOR ENVIRONMENTAL SCIENTIST IN SRK’S JOHANNESBURG OFFICE. She has over 10 years’ experience in research, training and consulting in the fields of ecology and biodiversity. Her consulting work has focused on coal mining where she has been involved in the compilation and management of multidisciplinary EIA projects and has served as independent environmental control for construction phase activities for mines and industry. Lancaster has a Doctorate in Socio-Ecology of small mammals from the University of Witwatersrand and is professionally registered with the South African Council for Natural Scientific Professionals.

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REJECT STREAM

Linings laid

The new brine ponds at New Denmark, Anglo American’s deep level colliery, are setting the environmental standard for reject stream water storage. HE BRINE PONDS, necessitated through an urgent directive received from the Department of Water Affairs, serve as an alternative storage method for the mine’s reverse osmosis reject stream. This reject stream was previously stored in an underground compartment within the mining area and on an ash dump. The mine’s underground compartment was almost at full capacity and there was concern that the constant application of water to the ash dump was resulting in an increased seepage and contamination of the groundwater in the area. One dam was completed in September 2012 and the second is due at the end of 2013. Due to the unavailability of natural clay required to line the dams, engineers recommended Kaytech’s geosynthetic clay liner, EnviroFix. Consultant Golder Associates decided that in this application, EnviroFix X800 would be the ideal product to replace the layer of natural clay. A South African

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manufactured geosynthetic clay liner (GCL), EnviroFix is produced by needlepunching a uniform layer of sodium bentonite between two durable outer layers of geotextile. Sodium bentonite is a naturally occurring clay mineral with a structure comprising charged platelets. Contact with moisture causes sodium bentonite to swell considerably and when this occurs under confinement, as in EnviroFix, it forms a lining with a low permeability equivalent to that of one metre of compacted clay. This reinforced liner prevents any contaminates from the mine from entering the ground water, thus providing a protective barrier, which is ultimately beneficial to the environment. Water from the New Denmark colliery will be pumped to a local topographical high point near the north dam, from where it will gravitate to the south dam. Both dams have been designed to comply with the Department of Water Affairs’ dam safety requirements. The needle punching

process in the manufacture of EnviroFix reinforces the otherwise weak sodium bentonite clay, thereby producing a completely uniform, reinforced GCL. The Thermal Lock process used to modify and permanently lock the needle-punched fibres into place results in unique properties such as increased internal shear resistance and long-term creep resistance. Protech was awarded the contract to install EnviroFix X800, and although the project is running behind schedule, it is expected that with this product’s ease of installation, the scheduled completion date will be met. EnviroFix is more durable over a wider range of installation conditions, and because it is needlepunched, it can greatly reduce the adverse effects of premature hydration during installation. It provides exceptional liquid containment and is also ideally suited for use in composite landfill liners and caps, and as a secondary containment barrier in aboveground tank impoundments.

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ENVIRONMENTAL RESPONSIBILITY

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An honorary distinction The Veolia Water Solutions & Technologies South Africa crystalliser at Ambatovy mine in Madagascar has received an award of distinction from the Global Water IntelligenceÂ Awards. HE DISTINCTION, which falls under the Industrial Water Project of the Year category, was handed to the leading water treatment

company at the annual awards ceremony, which was held in Spain this year. One of the largest ammonium sulphate evaporation and crystallisation plants in the world, the plant, which is capable of producing up to 200Â 000Â t of ammonium sulphate per annum, has been labelled one of the most advanced technical achievements in the field of industrial wastewater.

Zero o liquid d discharge The Ambatovy mineâ&#x20AC;&#x2122;s primary treatment system, part of the mineâ&#x20AC;&#x2122;s nickel and cobalt refinery, uses sulphuric acid, hydrogen sulphide and ammonia to extract valuable substances

from slurried ore. The Veolia-built plant successfully treats the effluent streams from this process using state-of-the-art evaporation and crystallisation technology, which extracts the valuable ammonium sulphate by-product for resale into the agriculture industry as a soil fertiliser. â&#x20AC;&#x153;The result is that maximum value is extracted from the ore, while all potentially harmful effluents are retained and treated within plant walls. This zero liquid discharge technology is fast becoming one of the worldâ&#x20AC;&#x2122;s preferred methods of improving sustainability while maximising profitability at the same time,â&#x20AC;? concludes Rencken.

40 IN S IDE M IN ING 1 1 / 1 2 | 2 0 1 3

When the stakes are high â&#x20AC;Ś In the field of mining the stakes are way too high to settle for anything but the best when it comes to choosing consultants to deliver on mining infrastructure projects. Mine operators need partners they can rely on, whether itâ&#x20AC;&#x2122;s for roads, rail, aerodromes, housing, water, environmental â&#x20AC;&#x201C; or anything in between. J&G understands this. Our quality statement says it and our track record confirms it. www.jgi.co.za

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Find out how: 011 663 3600 info.southafrica@veoliawater.com www.veoliawaterst.co.za

ENVIRONMENTAL RESPONSIBILITY

M IN N E W A ST TE

Exploring new civils Fraser Alexander Construction continues to expand its Cat scraper and allied earthmoving fleet to meet regional mining developments, recently winning the company’s largest order to date for the greenfield Husab uranium project in Namibia, the company tells Inside Mining. OW APPROACHING its 101st year, multidisciplinary company Fraser Alexander has, from inception, been at the forefront of mining developments in South Africa, playing a major role in the Witwatersrand Basin – a rich geological gold formation first discovered near Johannesburg in 1886. Spanning across sections of the Gauteng and Free State regions, from Johannesburg to Welkom, this is a precious metals footprint that has so far yielded an estimated 40% of all the gold ever mined worldwide. For Fraser Alexander, Johannesburg was evidently the place to start an engineering

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business targeting the mining industry and in the initial decades the company’s focus was on providing a tailings deposition service. Within a short space of time, however, the company was constructing and managing more than 70% of the dumps rising across the emerging Witwatersrand goldfields. In recent years, its tailings division has now been employed in re-mining them. Having gathered extensive experience since the company’s formation in 1912, Fraser Alexander delivers global bestpractice solutions internationally, working in territories that include South America

and Australia, as well as in up to 15 countries on the African continent. Wholly owned by JSE-listed entity Royal Bafokeng Holdings, Fraser Alexander currently fields its services across five divisions, namely Construction, Bulk Mech, Mineral Processing, Tailings and Water Treatment. A Fraser Alexander subsidiary is also being registered in Mozambique to target opportunities there, as well as to support Royal Bafokeng Holdings’ entity Mining Oil & Gas Services (MOGS), which has a strong presence in the country. Supporting all these divisions is Fraser Alexander Construction. A 9CE contractor in terms of the Construction Industry Development Board ranking, Fraser Alexander Construction is the turnkey civil engineering arm that services in-house projects, as well as targeting open market opportunities in the mining sector; furthermore, the industrial segments such as the petrochemical and power generation sectors. A specialist in mine civil engineering infrastructure,

ENVIRONMENTAL RESPONSIBILITY

Push loaded by either a Cat D8 or D9 dozer, the Cat 621G has a 17 m³ heaped capacity, with a rated payload of 23 950 kg

Fraser Alexander Construction’s offering is extensive, with a key downstream waste management focus. Areas of expertise include earthworks, ground level infrastruc-

alternative articulated truck and excavator loading options in terms of overall efficiencies,” says Jones. “Of course, there are exceptions; examples include contracts where hilly terrain or complex access routes necessitate the use of articulated truck haulage.” Given optimal conditions, scraper teams can generally move twice as much material as articulated truck and excavator teams, eliminating a lot of the processing work on the downstream end. “Instead of an articulated truck depositing its load in a heap at the other end, the scraper lays it out in a thin layer, so you don’t need a grader or a dozer on the processing side, you just need to run a roller over it,” Jones expands. “Combining the whole operation from cut to fill, there are clearly major advantages.” Push loaded by either a Cat D8 or D9 dozer, the Cat 621G has a 17 m³ heaped capacity, with a rated payload of 23 950 kg. “Wheel tractor-scrapers have long been considered the best method for moving

frontiers ture, retention dams, stormwater canals, silt traps, terracing, haul road design and construction, dragline walkways, mine rehabilitation and mine closures, as well as the construction of incline shafts/portals and the capping of waste dumps. Currently, around 10 projects are in various stages of construction across Southern Africa. Backing these extensive construction demands is a comprehensive earthmoving fleet, which includes a 20-unit strong Cat 621G scraper fleet – one of the largest in the southern hemisphere. These Cat scrapers are supported by allied Cat units that include latest generation Cat 730 articulated trucks and Cat 323D L hydraulic excavators. Deciding when and where articulated trucks or scrapers are deployed on tailings projects depends on the earthworks programme, explains Graeme Jones, Fraser Alexander Construction’s managing director. “Cat scrapers excel in cut and fill operations, which is why they are generally ideal for tailings dams built on relatively level terrain. In this application, they outstrip

large volumes of earth,” points out Barloworld Equipment Cat sales professional Craig Shepherd. “Recent improvements in design, materials and manufacturing have made current scraper models even more productive.” (Barloworld Equipment is Caterpillar’s Southern African dealer.) Loading a variety of materials ranging from topsoil to sand and clay at depths measuring up to 60 cm, a variety of cutting edges are available to ensure maximum scraper efficiencies. Turning back to Fraser Alexander Construction activities, the past and present contract order book underscores this division’s market leadership in its niche mining services sector. Recent projects include the construction of a new tailings facility for Northam A work in progress perspective of Fraser Alexander Construction’s contract at Northam Platinum’s Booysendal facility: commissioned in March 2013, the key project component entailed the building of a starter wall across a valley, requiring some 703 000 m³ of fill material

INSID E M INING 1 1 /1 2 | 2013 43

ENVIRONMENTAL RESPONSIBILITY

Platinum’s Booysendal project, which structural concrete construction, includwas commissioned in March 2013. Situing two silt traps, concrete-lined trapezoiated some 60 km from Lydenburg in the dal canals and a concrete rectangular canal Steelpoort valley, this project entailed the with a heavy-duty grid crossing. building of a starter wall across a valley, reMeanwhile, construction is at an adquiring some 703 000 m³ of fill material. vanced stage at Anglo American Thermal The dam wall stretches between two Coal’s Kleinkopje operation, situated near koppies, with the final wall height measuring up to 40 m from its inner face to the crest. The base of that wall is 300 m wide, which steps up to an 8-m crest on the top. A distinguishing feature of this structure is that it does not have a conventional return water dam; a barge pumping system is utilised to return water to the plant. Given Grrae a me e Jones es,, Fraser Alexand der the rough, mountainous terrain, articulated trucks were used for the Cons nstructi tion manag agin ing g di dirrector load and haul materials transfer. Another recently completed project is the St Helena tailings dam storage eMalahleni. Work entails the cleaning of facility constructed for Harmony Gold the plant’s return water dam. The dam Mining Company. The scope of works consists of two compartments, namely there included the construction of a new A (measuring 60 000 m³) and B (measurearth embankment starter wall measuring ing 30 000 m³). Phase 1 entailed desilting 6 km in length with a maximum height of compartment A to full working order. The 9 m, built on the footprint of a re-mined inflow into compartment B was then bydam. Fraser Alexander’s earthmoving passed with a diversion trench so that deplant moved around 1 165 012 m³ either silting could commence. using articulated trucks or Cat scrapers. Due for completion in December 2013 Also completed is a project for Optiis a second phase project for Anglo Gold mum Coal at Koornfontein, south of MidAshanti group subsidiary, Mine Waste delburg. Works there comprised mainly Solutions, at Kareerand, near Stilfontein. Kareerand Phase 2 includes the completion of an existing tailings dam that An aerial perspective of Fraser Alexander’s Fraser Alexander constructed in 2011. “In project at Xstrata Lion in Steelpoort, which entailed the construction of a lined tailings Phase 2, we will finish off the walls, extend dam and slag dams and was completed in the concrete-lined solution trench and September 2012 construct more filter drains,” says Jones.

Fraser Alexander completed the primary phase approximately three years ago. Another project nearing completion is a six-month contract entailing an environmental incline portal shaft closure at Anglo American Thermal Coal’s Nooitgedacht underground mine in Mpumalanga. Here a classic tailings dam is being created, building an earth starter wall and a basin. Fraser Alexander’s Cat scrapers were deployed to create the starter wall. A new contract at BHP Energy Coal Ponds’ Middelburg Water Treatment Plan includes the construction of blind ponds and holding dams forming part of a multi-contractor work package. Fraser Alexander is constructing two dams situated next to each other, each containing two brine cells and two holding cells, together with connecting pipelines that will transport water and brine waste from a new process plant on-site. Work has now also started at HCI Coal’s Palesa mine near Bronkhorstspruit, where Fraser Alexander is establishing a terrace on which discard will be placed by the mine. “Alongside these projects, we have now received a major boost to our order book following the awarding by Swakop Uranium of the Husab tailings dam construction project in September 2013,” says Jones. “In fact, this is Fraser Alexander’s largest contract award to date and we are very excited about this opportunity.” Running over a contract period of 20 months, Fraser Alexander will be mobilising 12 Cat scrapers at Husab, a greenfield opencast development situated near Swakopmund on Namibia’s west coast. Husab has a potential life of more than 20 years, with reserves of at least 280 Mt, making it the world’s second largest uranium mine at full ramp-up; the mine has the potential to produce 15 million pounds (6 800 t) of uranium oxide per annum. Mined ore will be fed into a conventional agitated acid leach process plant. “To manage Husab’s waste stream, Fraser Alexander will be constructing a traditional tailings storage facility, but on a very large scale,” Jones expands, adding that close to four million cubic metres of fill material will be required to build this extensive dam facility. “The Husab project certainly takes Fraser Alexander Construction to the next level as a global player in this complex field,” Jones concludes.

“D Deciiding g when and wh here e artic culatted trucks orr scra aperrs are deployed d on tailings s projec cts s depen nds on the earrthworks progra amm me.””

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“Irrespective of the discipline dominating a phase in a contaminated land project, we interpret results

through the lenses of local and international legislation, company reputation, ﬁnancial and social liability. The disciplines feed into each other for us to interpret into a package of consequence –

bringing science to boardroom decision-making”. Heidi Snyman Divisional Lead – Rehabilitation & Closure, Golder WISA Past-President Strategic Advisory Board of International Water Association Team member of eMalahleni Waste Water Treatment Plant Led research and compilation of SA Sludge Guidelines Assisted Coca-Cola with global good environmental practise for waste water treatment

Engineering Earth’s Development, Preserving Earth’s Integrity Ofﬁces across South Africa, Botswana, Ghana, Mozambique and Zambia. Tel: +27 12 364 4017 | hsnyman@golder.co.za | www.golder.com

ENVIRONMENTAL RESPONSIBILITY

TRAN N SDIS S CIPLINAR R Y C OLLABO O RATION

Interlocking integration for Daphnia pulex acute toxicity test organism

Environmental compliance has become increasingly complex and regulated, and is a non-negotiable requirement. Global consultant Golder Associates’ compliance solution lies in its transdisciplinary approach, placing it at the forefront of a new and emerging consulting era, writes Laura Cornish. ULTIPLE AND diverse envito address and prevent environment-harmronment-related elements ing situations,” outlines Carl Steyn, head of must be accounted for and soil science. assessed at a mine, especially The environmental team believes that when it comes to contaminated land issues. Golder differentiates itself from other enviTraditionally, environmental aspects are ronmental firms by offering the full suite of managed in isolation and often not integratenvironment-related services as an integrated in the long-term planning and daily oped solution package to clients. “Ultimateerations. This often leads to environmental ly, we also need to respect the fact that any mishaps throughout a mine’s operational life. environment-related work is a highly sensi“It has become essential to integrate all tive subject. Most mining companies do respecialist environmental expertise areas and spect the environment and want to manage recognise that different areas of the environtheir risks accordingly. These are the clients ment interlink with each other. This underwe want to work for,” Steyn continues. standing will ensure all issues are addressed, Source charactterisation n leading to fully compliant delivery,” says Understanding potential source threats resenior geochemist and head of ground chemquires understanding all rock and geologiistry, David Love. “Our ‘one team’ approach cal materials and how they have been chemat Golder focuses on compiling a single reically changed when mined and brought port with technical solutions outcomes and to surface. contribution that is more than the sum of Based on this evaluation, Golder idenits parts. The result is a single answer that is tifies constituents of concern (COC). This easy to understand, providing clear direction involves addressing issues such as: are the towards the solution.” contaminates from the source going to stay Golder applies the ‘source-pathwayor run; what is its quality and volume input receptor’ concept as part of its contaminatinto groundwater resources; which contamed land solutions. In essence, this involves inates are going to mobilise and in what identifying current and potential organic state or form will it be when it reaches the and inorganic contamination sources on-site receptor. “We can predict the chemical im(such as waste, spillages, processing plants). pact of mining on rocks over a lengthy periThe receptors or areas that will be impacted od of time through and long beyond the life by identified sources can then be pinpointathway (water, air, soil) of a mine. We have mo models and tools, and ed as well as the pathway ca conduct laboracan connecting the two.. The reality is that 77 environmental to and on-site extory “Through this meth-national Acts have been promulgated pe periments based on odology, outcomess from 1995 to 2014. In fact, environmental o ac actual climate condican be translated to legislation has doubled every 20 years since the m tio tions,” explains Love. clients, enabling them 1940s – Charlaine Baartjes, A major contamito make informed de-MD at EcoPartners w na nation source, often cisions about how

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forgotten or neglected is soil. “We do a lot of chemistry evaluation work on the soil in a mining area, considered to be 1.5 m deep wherever plants are growing. Soil and wetlands have huge environment functionality. Both act as buffers for toxins, meaning they disable toxic waste transfer. At some point, however, the buffer capacity will be exceeded and this impact has to be considered in relation to the rest of the environment,” Steyn continues. The key is to understand when soil is contaminated naturally and unnaturally. “It is also imperative that soil is no longer seen as the sink for pollution.” Soil should be elevated to the same status of wetlands as it too is an important environmental resource providing environmental goods and services.

Pathway analyyses Within a mining context, water resources are considered the most common contamination pathway. Groundwater divisional leader and senior geohydrologist Gerhard van der Linde evaluates distribution and movement of groundwater in the soil and rocks. “Understanding groundwater flow and contaminant properties, soil and rock attenuation, flow rates to where and by when requires preferred groundwater flow and solute transport models,” says Van der Linde. The most important aspect is to understand the aquifer flow and transport properties, which are captured in a conceptual groundwater model. This conceptual model is then used as the base for numerical flow and transport modelling, predicting concentrations of COC in the groundwater at potential receptors.

ENVIRONMENTAL RESPONSIBILITY

contaminated land solutions Receptor characterisation

within that category. Our ultimate intention triple bottom line negatively. Through a comUnderstanding the sources and possible pathis to provide clients with strategic advice, bination of prevention and early intervenways are essential to predicting and determinconstantly evaluating the changing legislative tion, environmental and financial liabilities ing what environmental risks is are minimised. The truth is that associated with what COC for the unfortunately there are many “O Our ‘one team’ approac ch foc cuse es historic legacy sites with impacts receiving environment, says ecologist Peter Kimberg. that have advanced significanton comp piling a single repo ort with “In order to offer the client an ly. In these cases, we mobilise a tech hnica al solutio ons s outcom mes and integrated, all-encompassing antransdisciplinary team of highly swer to the management of conconttribu ution morre than the e sum m off qualified scientists and engineers tamination, the consultant has to quantify the impact and design itts pa arts.” David Love, senior geochem mist to know which questions to ask, measures to arrest and reverse the including what is the risk of a pareffects. We have developed tools and d head ad of grrou o nd chemistry, Go Golder ticular COC at that concentration to accurately cost remediation to a specific receptor, bearing in programmes. In large projects, environment in order to advise clients on how mind that it is seldom that one COC affects this requires financial modelling and cash flow to manage this risk in an environmentally reonly one receptor.” predictions, without which the viability of the sponsible manner,” says Heidi Snyman, rehaA full-scale laboratory is essential to receptor entity itself is threatened leading to unplanned bilitation and closure divisional leader. analysis, as are source and pathway charactericonsequences such as job losses. “It is often “Our integrated contaminated land solutions sation. Golder has a fully accredited laboratory at this stage that environment-related issues offering means that we are able to provide clito test and determine kinetic parameters and reach board level. This is when the science beents with assessments, on different tiers with the effects of a mixture of contaminants on hind the financial answer needs to be solid and their respective legal connotations, delivered test organisms (toxicity). justifiable. The link is often overlooked that in a package that the client understands.” Integrating field work, modelling and laboragood science feeds into enhanced boardroom Contaminated land issues can affect the tory tests delivers optimal results in terms of decision-making,” Snyman concludes. best understanding mining’s environmental impacts. “If the results in the laboratory reflect the result on-site, then site-specific thresholds can be established,” says laboratory manager Bridget Shaddock. “Our tests are used to detect toxic substances by using living organisms as indicators of environmental quality. Single-species toxicity tests, in conjunction with chemical and ecological measurements, create a holistic approach for effective water resource management. All toxicity tests are conducted in environment-controlled rooms using standard techniques. Our experience includes mine water analysis, kinetic and static geochemical testing with both water and solid samples.

Understanding how the environment impacts the bottom line “Clients understand corporate risk terminology and environmental responsibility falls Contaminated land management *Identification of these elements enables remedial action: either stopping the source from getting to receptor using barriers or moving the source so it does not reach the receptor

INSID E M INING 1 1 /1 2 | 2013 47

ENVIRONMENTAL RESPONSIBILITY

M I N ING WA A S T EWATER

Walking a fine line The mining industry is a heavy water user and producer of wastewater. Effective water management is therefore critical to the sustainability of companies operating in the sector, and companies are required to walk a narrow line between the interests of their shareholders, the communities where they operate and the broader environment. Compiled by Michael Avant-Smith, commercial director at NuWater HEN IT COMES to water in the mining sector, the challenges faced are threefold: water security, environmental compliance and sustainability.

even more so, than those of water shortages. The scope of water and wastewater treatment requirements in mining can broadly be categorised as follows:

Water security In order to develop and finance a new mining operation, it is critical that a reliable supply of good quality water can be secured throughout the life of the mine in order to satisfy extraction and processing requirements. This requires the identification of suitable water sources and securing the longterm rights to these. Sources may include surface water such as rivers, lakes and dams; underground aquifers and in certain cases even seawater. Some form of water treatment may also be required to condition the water for a specific application.

Environmentall compliancce Miners are increasingly being held to stringent wastewater discharge regulations. This necessitates additional investment in wastewater treatment infrastructure to ensure both new and existing operations comply with these regulations. Critically, responsibility for wastewater treatment prior to discharge back into the environment goes well beyond the useful life of the mine, as mine drainage may continue for years and even decades after mine closure.

Sustainability Miners have always relied on political support to secure the necessary licences to operate in specific countries. In our modern world where information is readily available

48 I NS IDE M IN IN G 1 1 / 1 2 | 2 0 1 3

and social networks shape perception, the acceptance by local communities for the development of new operations, as well as the smooth operation of existing operations, is becoming even more critical. In this context, both competition for existing water resources, as well as expectations on miners to preserve the quality of existing water resources, are growing and becoming more critical to the sustainability of mining operations. The impact of local failures by international mining companies is also amplified internationally and local brand damage can quickly lead to contagion of plans and operations on the other side of the globe.

Scop ope of water and wasttewater treatment The scope of water and wastewater treatment in the mining sector is becoming increasingly varied and complex in order to support different operating environments. The problems of too much water are as challenging, or

• Securing quality supply – In order to address operational requirements, water secured from available water sources may need to be treated to condition it for a specific application. Treatment may be basic to ensure the protection of process equipment, or more extensive to ensure the chemical suitability of the water. In the case of limited supply, and where location affords, seawater may also be considered. In this case, desalination is required in order to make the water usable from an environmental and process perspective. • Mine drainage – Mine drainage (also referred to as acid mine drainage) is a major problem for mines both during the useful operational life of the mine and well after mine closure. This wastewater must be collected and contained before being treated, such that it can be safely discharged back into the environment. The same wastewater treatment technologies must be applied to ensure the levels of suspended and dissolved solids fall below the regulated environmental discharge limits. • Zero liquid discharge – Possibly the greatest challenge for mines dealing with wastewater is the handling of waste streams from wastewater treatment processes. While these waste streams are highly concentrated, they still contain large amounts of liquid, making them difficult to manage and store

ENVIRONMENTAL RESPONSIBILITY

safely. The final separation of liquids from solids in these waste streams is referred to as ‘zero liquid discharge’ (ZLD), meaning that all remaining water is fully treated, leaving only solid waste for further processing, storage or safe disposal. Achieving ZLD is technically challenging and requires significant amounts of energy, making it very expensive (both capex and opex).

Complex treatment challenge Mine wastewater presents a significant treatment challenge, as the water chemistry is often complex and dynamic. In addition, wastewater may also be toxic. Common wastewater treatment considerations are pH adjustment, heavy metals and suspended solids removal, and the removal of dissolved solids, or desalination. Effective treatment of mine wastewater is also costly as it generally requires a significant amount of equipment and consumes large amounts of energy. Solids removed during the treatment process must also be managed. The opportunity may also exist to remove valuable minerals from the waste streams, which can help offset treatment costs. The dynamic nature of mine wastewater also requires more flexibility in the treatment plant than for more conventional wastewater treatment infrastructure. Treatment capacity may need to be increased or decreased over time to match changes in wastewater volumes. Addressing these challenges requires an innovative and highly flexible approach. In assessing wastewater treatment technologies and service providers, miners must therefore consider the following aspects of any proposed solution:

quickly and affordably. A modular solution therefore provides the best option to achieve flexibility and to ensure redundancy.

Solution scalability The scale of the wastewater treatment requirement for an individual mine, or cluster of mines, can run to tens of millions of litres per day. The treatment capacity requirement can also change over time depending on operational and climatic conditions. Plants must therefore be readily and rapidly scalable. This includes the ability to reduce capacity in a practical manner to avoid having underutilised equipment that needs to be financed. The nature of the treatment plant must therefore be such that capacity can be added or removed without impacting existing treatment requirements.

More than tecchnology The mine wastewater treatment challenge goes well beyond individual technologies. Complex water chemistry requires multiple technologies to be integrated into a single robust and reliable system. This requires expertise and creativity from systems integrators. In addition, mines are often demanding environments in which to operate. Solution providers therefore need a level of logistics capabilities to adequately service customer requirements. Mines and mining companies also increasingly expect water solutions to be delivered as a complete solution without the need to invest their own capital in the required treatment equipment. This therefore necessitates creative commercial offerings and financing solutions on the part of the service provider.

Solutions and services providers must therefore become more sophisticated and integrated to ensure they can offer the solutions and services demanded by their mining customers. This may include strategic partnerships with specialist technology providers, financial services and logistics companies.

The future of mine wastewater treatment While the requirement for wastewater treatment in the mining sector will continue to grow rapidly, driven primarily by the increased enforcement of environmental regulations, there continues to be reluctance on the part of mining companies to make the necessary investment in treatment solutions until they are forced to do so. The reasons for this are probably less to do with a lack of concern for the environment and more to do with affordability – large-scale mine wastewater treatment, particularly when including the requirement for zero liquid discharge, is simply too expensive. Wastewater treatment solutions and service providers to the mining sector should therefore be taking the lead in addressing the affordability issue in order to accelerate the adoption of these solutions and services in the mining sector. By creating a framework whereby mining companies can better understand the wastewater treatment solutions and services on offer, their application to address specific issues they face and the pricing of these, the industry is also more likely to make the commitments necessary for providers to develop more affordable technology and financing solutions.

Solution comp pleteness Solutions often require the integration of multiple technologies to address the specific chemistry of the mine wastewater in question. Integration of technologies from different providers is complex and often troublesome. Therefore a single systems integrator is easiest to manage and presents the greatest probability of success.

Solution flexibility As the chemistry of mine wastewater changes over time – in some cases rapidly, depending on changes in operational and climatic conditions – the treatment solution must be able to adapt accordingly. This may involve minor process changes or extensive reconfiguration of the plant. It is therefore critical that the nature of the plant is such that the required changes can be implemented

ABOUT NUWATER NuWater is a specialist mine wastewater treatment solutions and services provider and has executed world-class projects for leading mining companies based on its large-scale, rapidly deployable and redeployable modular packaged plants. NuWater designs, builds, owns and operates plants, putting the company in a good position to understand the technical, logistical and financial challenges facing miners and water treatment service providers in the sector. NuWater is growing a network of service providers and mining companies to develop affordable, robust and reliable wastewater treatment solutions and services for the mining sector through collaboration.

INSID E M INING 1 1 /1 2 | 2013 49

ENVIRONMENTAL RESPONSIBILITY

VALUING NATURE

The conservation key

Environmentalists don’t often get involved in the mining industry. Jeffares & Green’s environmental manager, Magnus van Rooyen, believes, however, that it is in the mining sector that he can best make the biggest environmental difference, writes Laura Cornish. SEE THE potentially damaging results that mining can have on the environment, but instead of shying away from the fact, I am only motivated further to provide a service that delivers preventative measures on the greatest scale, to ensure that the environment is preserved as far as possible,” he states. With this approach and motivation as his driver, Van Rooyen has been putting his strong scientific background in geology, botany and zoology to work at South African civil, structural and environmental engineering firm Jeffares & Green (J&G). Over the past 90 years, J&G has focused on providing the highest quality of consulting engineering services for the benefit of the community and the environment and introduced its earths and sciences division 15 years ago. “The way

50 I NS IDE M IN IN G 1 1 / 1 2 | 2 0 1 3

to conserve nature is to give it a value,” says Van Rooyen. J&G’s environmental work (in mining specifically) arose from humble beginnings where it started consulting on borrow pits, sandpit and quarry permit applications. Work on coal mines in the northern KwaZulu-Natal region has subsequently seen it develop strong relationships and a range of services in the coal industry. J&G's earth sciences division specialises in geology and geotechnical engineering, hydrology, geohydrology, ecology and biodiversity, project management and other specialist areas, such as wetland monitoring and contaminated land and waste studies.

A sp s ecialist ser ervi v ce pro rovi vid der Within an environmental context, although it has done work for major mining

companies, J&G has mostly catered to midtier and smaller mining companies, including those focused on Africa. “Often found in remote regions, they have different approaches to work and must find innovative solutions to operational and financial problems. Our company ethos is to help meet the needs of these clients, match their innovative approach and walk beside them on a long and hard road to production success,” Van Rooyen highlights. “And we make things happen because we are flexible enough to adapt and deliver.” Van Rooyen adds that working with mining companies in Africa, where poverty and unemployment levels are high, is extremely rewarding. “While mining undoubtedly impacts the environment, companies contribute greatly to their neighbouring communities, often providing them with a lifestyle

ENVIRONMENTAL RESPONSIBILITY

far better than what they had before. When I see the results of this, it reminds me why my environmental role is so important, ensuring mines can operate responsibly while delivering great upliftment to people. “From a development or start-up point of view, smaller mining companies face the greatest challenges, particularly with regards to environmental requirement costs. The volume of regulatory requirements and amount of contradiction between the Department of Mineral Resources, the National Environmental Management Act and the Department of Water Affairs makes it financially difficult to comply. Our job is to help these companies overcome these challenges as best we can.” J&G is applying its environmental philosophy to a number of projects at present, including: • increasing the footprint and raising a dam wall in northern Mozambique • community resettlement projects for an iron ore mine in Guinea • performing the EIA for a new magnetite mine in Namibia (also a resettlement study) • due diligences, water use licences, EIAs, etc. for local coal projects in Mpumalanga and northern KwaZulu-Natal.

“The way to conserve nature is to give it a value.” Magnus van Rooyen, environmental manager, Jeffares & Green

OPPOSITE AND BELOW While mining undoubtedly impacts the environment, companies contribute greatly to their neighbouring communities, often providing them with a lifestyle far better than what they had before RIGHT J&G specialises in all mining related environmental areas in Africa INSET Magnus van Rooyen develops close relationships with the locals in Africa

INSID E M INING 1 1 /1 2 | 2013 51

ENVIRONMENTAL RESPONSIBILITY

Rehabilitating smarter, not harder Mining rehabilitation may be a necessary cost, but VBKom Rehab optimises the process to suit any budget, writes Vicky Sidler. BKOM REHAB is part of an independent mining engineering consulting firm with a focus on rehabilitation designs and scheduling. “What sets us apart from the rest is that we physically plan the rehabilitation with mining software, normally used for mine planning. We design and schedule the broken topography into the desired topography afterwards,” says John Hough, VBKom Rehab’s managing director. VBKom Rehab offers a five-tier approach to rehabilitation that utilises art mining engineering methodologies to facilitate the

in-depth planning of the rehabilitation cycle from its current state to the desired landscape. The acronym REHAB reveals the company’s approach, which includes: • Rehabilitation (design plan implement) • Environmental (EIA-related offerings) • H20 (focusing on water quality and amelioration) • Air (reducing poor air quality caused by burning mines) • Botany (plant growth and soil conditioning in rehabilitated areas). This includes a total mining schedule of equipment costing and material balance, which all

works together to ensure optimised costing and affordability. “Optimisation can be done for the relative cost of rehabilitating a few hectares,” says Hough. “In the current financial market, it is important to spend the money where it will actually make a difference.” Concurrent rehabilitation, the process of backfilling during the mining process, is a primary focus of the Department of Mineral Resources, says Hough. “The technique brings down your total cost of mining. We also look at the z-elevation ‘above mean sea level’ between ramps to ensure that there is enough material to fill any final voids.

52 I NS IDE M IN IN G 1 1 / 1 2 | 2 0 1 3

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ADVERTORIAL

GEOLOGICAL INVENTORY IN REAL TIME?

MineRP’s ERP first International mining software company MineRP is creating waves with its recent announcement of a brand-new system and method for mineral asset management, accounting and analysis.

HE EXECUTIVE vice president: Strategy for MineRP, John Megannon, says: “We have spent a significant amount of time over the past few years positioning our products and company to be the world’s premier platform for enterprise interoperability solutions focused on the mining industry. The GeoInventory patent represents the culmination of this work and also exploits the latest in big data management technologies available.” Mining companies are very often vast organisations, with information required from many varied data sources for the purposes of modelling and planning, operational execution, continuous improvement and multifaceted management reporting and governance requirements. This reality creates an immense demand to integrate information sets from across the organisation, including mining technical data (created in technical domains such as geology, mine planning, survey, etc.) and commercial data created in supporting

business domains such as finance and accounting, human resources, supply chain management. While commercial enterprise resource planning (ERP) solutions have largely succeeded in the integration of the supporting business functions, such integration is much harder to achieve in the mining technical disciplines, where fragmented specialist systems are still the standard. The non-integrated nature of the mining technical systems and services domain leaves significant areas (including mineral asset valuation) open to interpretation by technical and commercial disciplines, generally represented by a competent or qualified person within each mining organisation. A specific issue related to this reality is the fact that mining companies are unable to continuously track the status of resources and reserves. This is mainly due to the time-consuming nature of manually integrating and interpreting the data that describes the state and status of the mineral asset. Among other things, decisions regarding the application of capital to the

mineral assets are impeded by the lack of integration between the financial and mining technical domains, as is the tracking and reporting against capital projects at a granular level.

The MineRP GeoInventory invention As shown in the diagram, MineRP has developed (patent pending) a system and method for mineral asset management, accounting and analysis through: • amalgamating and integrating big volumes of fragmented mining technical data sets into a spatially referenced, standards-based mining technical database • leveraging the ability to process big volumes of data in an efficient manner, employing current and future big data platforms, including but not limited to socalled in-memory databases • continuously translating the effect of changes in the state and status of the real mineral asset, as described in the integrated, spatially referenced mining database, into standard stock management transactions for processing in standard inventory management systems.

Early industry response MineRP has started introducing the GeoInventory Invention to selected global clients and also did a specific proof of concept of the underlying technologies using the SAP HANA (high-performance

MineRP GeoInventory translates all mining activities into real-time geological inventory transactions

54 I NS IDE M IN IN G 1 1 / 1 2 | 2 0 1 3

ADVERTORIAL

analytic appliance) in-memory database management system. This resulted in SAP inviting MineRP to its recent SAP Industry Advisory Council for Mining annual meeting in St Louis, Missouri. Feedback from top mining companies at this event as well elsewhere is overwhelmingly positive. The resulting mineral asset inventory provides mining companies with a range of business-critical optimisation opportunities, including: • The ability to provide real-time, reliable resource and reserve reporting in

compliance with regulatory codes, as and when required. • The ability to provide financial and other business input into the production planning processes through analysis of the mineral asset inventory. • The ability to visually integrate operational and commercial reporting. • The ability to vastly improve the speed and accuracy of reserve and resource audits through reliable access to data sets and transaction records in both the mineral asset inventory and the

integrated underlying mining technical data sets. • Scenario-building and testing, especially as it pertains to the interaction of the commercial and mining technical domains. • The ability to do real-time analytics on any aspect of the mineral asset, whether technical, financial or combined. For more information about MineRP’s revolutionary GeoInventory solution, please contact Empie Strydom at estrydom@ minerpsolutions.com

INSID E M INING 1 1 /1 2 | 2013 55

Massive savings available with the latest release of MineRP’s Mine2-4D v15. T The new Mine2-4D combines with SpatialDB, SSpatialDash, SpatialAnalyzer, MineCAD and EPS tto form a complete mine planning and scheduling system that delivers cost and performance improvements like no other solution. • •

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PIPES & PUMPS

PIPING FROM PIT TO PORT

Emerging trend breeds novelty

MP IS CELEBRATING its successful involvement in one of the largest slurry transport pipeline projects in Africa. Moroccan state-owned phosphate mining company Office Chérifien des Phosphates is investing US$5 billion (R49.16 billion) in a massive expansion of its operations and capacity. Part of the expansion involves the construction of a 230 km long pipeline that will link its mine

The trend to transfer slurry from pit to port is increasingly moving from road and rail to pipeline. This is creating new opportunities to provide new products and technologies for more demanding applications. South Africa’s polyurethane specialist UMP is at the forefront of this industry development with a worldfirst project already complete, writes Laura Cornish.

in Khouribga to the Port of Casablanca. The pipeline will replace the need to transfer product by rail, and facilitate an exponential increase in volume that could be transported, which otherwise would be very difficult to achieve with rail. sists of a segment of The pipeline consists 187 km, 36 inches and is the largest diamver built for slurry, with eter pipeline to be ever a segment of 39 km of 12 to 20-inch

pipeline, including pump stations and storage facilities. In February this year, Turkey-based construction company Tekfen Construction & Installation awarded UMP the contract to supply several specialised polyurethane linings for pipe BELOW Each pipe bend varies between 3.5 and 5 t and stretches up to 6 m in length

INSID E M INING 1 1 /1 2 | 2013 57

PIPES & PUMPS

ABOVE The pipe bends were imported to UMP’s facility from Germany LEFT Working on the lining inside the pipe bend

bends, ranging from 350 nominal bore (NB) to a significantly large 900 NB. UMP director Trevor Carolin explains why the project is so significant: “Our largest project to date was fitting linings with a 500 NB or less, making this a project first for UMP. The large bends required a 12 mm thick lining, fitted perfectly to the arc’s shape. This necessitated investing in the design of specialised tooling to line the pipe bends to the required thickness. The pipes also have varying degrees of tolerance in terms of radius, which means tooling adjustments for this

58 I NS IDE M IN IN G 1 1 / 1 2 | 2 0 1 3

fact h a d to be catered to. Bearing this in mind, the abrasive tolerance of the lining could not be compromised,” he continues. Two new ovens were built, a forklift hired and an additional 10 workers employed to assist on the project. Special casting tools were also manufactured and about R2.8 million invested in the manufacture of a complex tooling system to get a mould in and out of the bend. A total of 89 pipe bends had to be lined, equating to about 250 t of steel work. Manufactured and imported from

Germany, the weight of each pipe bend varies between 3.5 and 5 t and stretches up to 6 m in length. Through trial and error, UMP reduced the mould set-up time from three days (when it started) to just eight hours. Specialist slurry pipe engineering firm Patterson & Cooke designed the pipeline and, according to Carolin, is one of only two such companies in the world that understand slurry behaviour and subsequently slurry transport systems. “Following a number of unsuccessful attempts with other manufacturers from around the world, the client approached UMP to develop a polyurethane solution that offers superior abrasion resistance against the slurry and can tolerate a lot of bend turbulence. The slurry will move through the pipeline at a pressure of over 120 bar and will tolerate such conditions for at least 20 years,” Carolin explains. With the project complete, and the result a new lining technology

RIGHT A total of 80 pipe bends had to be lined

developed, UMP hopes to emerge as an international leading company in the supply of polyurethane linings. “We started casting bends in June and despite the challenges in getting the product to specification, were finished in October with the final pipe bends recently delivered to site.” The initial quotation for the project was signed in August 2012, and an order for the trial product in November 2012. With the final contract signed in January 2013. In addition to the polyurethane lining, UMP also supplied high-density polyethylene lining for the project’s test loop at the port to reduce slurry velocity. Thanks to UMP’s international ‘break through’ in polyurethane lining technology for pipe bends, the company is designing its own standard range of polyurethane linings for pipe bends for diameters up to 750 mm. “We now have the tooling in place and the training necessary for the job, which places us at a huge advantage for future projects of a similar nature. We are in fact already

working on another project in Africa with many parallel project features.” Carolin is also confident that new business prospects are available to the company as a result, particularly across Africa, North

America and South America. “We are already in the process of establishing a division in Ontario, Canad; the first step in a long line of proposed expansion opportunities for UMP,” he concludes.

INSID E M INING 1 1 /1 2 | 2013 59

PIPES & PUMPS

Launched in Germany, designed in SA In early September 2013, German pumps and valves manufacturer KSB launched a back pull-out design (RPHmdp) zero-leakage mag-drive pump series, designed by the company’s South African engineers.

HE HORIZONTAL, radially split volute casing pump, designed and manufactured to US standard API 685, has been developed to reduce maintenance costs and ensure a maximum service life. It combines the proven and durable RPH hydraulic system with a state-of-the-art magnetic drive. The pumps are primarily used for handling harmful fluids such as hydrocarbons containing benzene, which are subject to very strict emission regulations. They are, however, also

well-suited for the transport of clean, explosive, toxic and valuable fluids in petrochemical plants and refineries. Patented plain bearings ensure that the heat is well dissipated and particles that have penetrated the magnetic coupling chamber are expelled. These technical KSB includes a mag-drive pump type series in its API range

features help to increase the pumps’ service life. The type series is designed for flow rates of up to 300 m3/h and a maximum head of 270 m. The permissible operating temperature ranges from -40 to +300°C. Final pump set assembly is performed in Brazil, India, Argentina, South Africa and Germany, ensuring that the pumps are available worldwide and can be easily matched to the respective local requirements.

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Solid dependability

Metso slurry pumps provide trouble-free operation

Metso slurry pumps are available in a range of sizes and configurations to suit your needs – from the toughest mill discharge and dredge pumps to simple transport applications. Our rugged hydraulic wear parts incorporate the highest quality hard metal, rubber and corrosion resistant material for continuous, cost-effective operation in abrasive environments. You can rely on Metso’s equipment and reputation.

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Pumps Valves Systems

One stop shopping – for every level of mining An essential part of any mining infrastructure, KSB pumps help ensure costeffective, continuous operations. Our solutions always focus on the customer, so KSB strives to make pump and valve planning easy by providing products for every step of the mining process – solutions that have proven themselves over time. From the heart of the mine right to the end product, KSB powers the future of high quality, safe mining. • • • • •

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CASHING IN

DRC’s pump patriarch The Democratic Republic of the Congo’s copper belt is flourishing, despite the global cash-constrained economy. Equipment supply companies that are successfully cashing in on the region’s project opportunities are reaping the benefits, writes Laura Cornish.

OCAL PUMPS, CYCLONES and valves manufacturer FLSmidth Krebs, a company under the global FLSmidth brand, is reaping the rewards of its growing footprint in the Democratic Republic of the Congo (DRC). Over the past two years its slurry pump installation base has increased from zero to well over 100 and “there are many more DRC project orders in the pipeline,” indicates FLSmidth Krebs’ general manager, Brad Moralee. The company boasts solid working relationships with some of the country’s biggest international mining houses. For one client, FLSmidth Krebs is supplying all mill discharge pumps and tailings pumps for the new project. “We are starting to reap the rewards of our focus on tailings slurry pumps. This is a relatively new area for Krebs and a key growth strategy identified two years ago,” the Moralee mentions. He is particularly proud of the company’s slurry pump supply contract for TSX-listed copper/cobalt company Katanga Mining’s Kamoto project. “Our order entails two 16 x 14 millMAX UMD centrifugal slurry pumps and two 14 x 12 millMAX pumps, for the milling circuit. We are also supplying ten 20 x 18 millMAX flotation duty pumps for other areas of the plant as well.”

62 I NS IDE M I N IN G 1 1 / 1 2 | 2 0 1 3

The millMAX UMD was introduced to the market about two years ago and is performing well. The UMD design combines the patented millMAX suction side sealing technology incorporating computational fluid dynamic research. According to Moralee, it out-performs the competition in both power consumption and wear life, lasting longer than any other mill discharge pump. The Kamoto contract was awarded in February 2013. To date, all flotation pumps have been dispatched to site, and the supply of the mill circuit pumps will be complete in December 2013. “These are the first significant pump orders that FLSmidth Krebs has secured with Kamoto/Katanga, which builds on our historical cyclone installations and falls into our overall strategy to further increase our presence in the DRC,” Moralee highlights. While the DRC is traditionally recognised as a copper/cobalt mining territory, it is also home to one of Africa’s largest new gold mines, Kibali, jointly owned by Randgold Resources and AngloGold Ashanti. It represents one of the largest Krebs pump supply contracts in Africa. LEFT A Krebs vMAX pump installed in a gold plant in the DRC BELOW Final assembly of Krebs millMAX slurry pumps for a gold plant in the DRC

PIPES & PUMPS

Following a lengthy tender process, FLSmidth Krebs was awarded the entire pump supply contract for Kibali, amounting to more than 110 units in total. “The order is a combination of millMAX, slurryMAX and vMAX (vertical spindle) pumps, all of which were transported to site between December 2012 and June 2013,” says Moralee. Commissioning is currently under way and related spares already consigned to site. Moralee admits that the project was not without challenges. He says they had to meet a very tight deadline, which required a certain level of compensation for a lengthy logistics process. “We already consider the contract successful, pulled out all the stops and developed even stronger working relationships with both Randgold Resources and EPCM contractor DRA Minerals Processing.” FLSmidth Krebs’ Kibali contract is proof that service delivery and relationship building is the key to repeat business. The Kibali project is, in fact, the company’s second

supply contract for Randgold Resources. “We first supplied all the pumps to Randgold Resources’ Tongon project in Ivory Coast.” The company services its DRC-based clients from its Johannesburg office but works in conjunction with its approved Zambia and DRC representative company, Liquid

Rock Process Solutions. Liquid Rock is fully equipped and staffed to handle all Krebs-related project work, from service exchange and stockholding to on-site support. “Support in general has become increasingly important to FLSmidth Krebs. We are gaining an increasing number of maintenance contracts, which further boosts our ongoing growth aspirations,” concludes Moralee.

RIGHT AND INSET The Krebs millMAX 26 x 22 UMD pumps in the assembly area

INSID E M INING 1 1 /1 2 | 2013 63

We’re passionate about mining

It’s our passion for mining and dedication to our customers that inspires us to deliver excellent customer service. At Mining and Rock Excavation Technique we’re driven to optimise our customers productivity. www.atlascopco.co.za

PIPES & PUMPS

MINERAL SANDS IN SENEGAL

Providing smoothflowing channels Weir Minerals Africa has pulled out all the stops across multiple product ranges, including pipes and hoses, to help reduce the time delays in project start-up for a new large-scale mineral sands project in Senegal, writes Laura Cornish.

ERVICE DELIVERY, relationship including a technical manager, and did an building and quality products audit on the equipment and provided a have seen Weir Minerals’ iniscope of work. We were awarded the contial project involvement expand tract,” says Weir Minerals’ rubber products substantially since its first order and inimanager, Ronald Govender. tial project involvement. Today, it repreIt was, however, the contracts that followed sents the company’s largest pipe contract that have shown the company’s true capabilin Africa. ities and commitment in delivering above Considering project design first started and beyond for its clients. “The project was five years ago in 2008, construction delay experiencing sizing problems with its hoses, is considered the project’s biggest conwhich was putting additional time delays on straint, which has been ongoing in some the project. Thanks to our previous contract areas for up to 18 months. and guarantee in meeting tight deadlines, w were contractWeir Minerals first we e in July this became involved in ed As the chemistry of mine wastewater y the project after the year to supply changes over time, in some cases rapidly R client requested a quoR8 million worth depending on changes in operational and o tation to provide rubof custom-declimatic conditions, the treatment solution must be able to adapt s ber lining for some of signed softwall accordingly - Michael its process equipment. floating dredge Avant-Smith, commercial h “We immediately mohoses,” Govender director at Nuwater o bilised a team to site, outlines.

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The hoses have a 405 NB (nominal bore) and are 11.8 m long. The last batch is in final stages of manufacture and some last minute additional items such as the gimbal ring hoses will be completed to meet the client’s target delivery requirement for the original order. Weir Minerals was, in fact, involved with the original hose designs at the project’s conceptual phase. The company was also asked to tender on the supply of about R10 million worth of rubber lined pipes (critical pathway from the dredging operation to the process plant) and HDPE piping, originally meant to come from Spain and the UK. Again, the lead time constraint was a problem. “With Weir Minerals on board, the supply time was reduced from what would have taken as long as six months to only three.” The pipes and fittings (straights and bends) range from 100 to 600 NB and were supplied with all ancillary items such as

PIPES & PUMPS

FAR LEFT A bird’s eye view of the hose manufacturing bay at Weir Minerals Africa’s Alrode facility LEFT The hose manufacturing team, along with Ronald Govender, Ajith Bahadur and Abraham Mofokeng at Weir Minerals Africa’s Alrode facility

nuts, bolts, gaskets and pipe supports. The volume of rubber lining equates to about 8 t. Meeting the deadline meant deploying the rubber lining work to five of Weir Minerals’ rubber shops that form part of the company's extensive service centre network. Rubber lining is quintessential for mineral sands operations, which are recognised for their abrasive, resistant nature. Govender

says the Linatex rubber products are market leaders in abrasion-resistant rubber. “In a similar dredge operation where the plant had hit calcrete, competitor hoses lasted no more than four weeks. Linatex hoses by comparison lasted up to four months due to superior quality attributable to their high molecular strength liner and long service life.” Piping was incorporated into the Weir Minerals stable in 2010 following its acquisition of the Linatex business. All the products were manufactured and supplied in South Africa and then transferred to site. Govender admits that one of the biggest project bottlenecks has been logistics. “It takes as much time to get items to site as it does to produce them.” To compensate, Weir Minerals upgraded its hose facilities and purchased additional

machines, which was a fair amount of capital investment for a single project. Weir Minerals’ contract also included the supply of a 1.1 m (internal diameter) self-floating dredge hose and preformed hose bends in 2012 and all the pumps as well, including one of the largest mill circuit pumps in the company’s range, the Warman MCR 750 pump.

Extending its African branch service offering Govender says Weir Minerals is currently rolling out its rubber lining range to all of its African branches and service centres, to support the growing African market. “The Linatex business has grown threefold in the African market since the acquisition and Weir Minerals has made significant investments into the Linatex manufacturing facilities to support this growth. Weir Minerals Africa has 21 branches and service centres throughout Africa and the Middle East, and we are continually investigating opportunities to set up facilities closer to our customers to further improve our service levels,” Govender concludes.

INSID E M INING 1 1 /1 2 | 2013 65

MEETING THE

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PIPES & PUMPS

WHY PE100?

A new look at PE pipe systems for mining A number of contracts to supply pipework systems to major mining projects in Kenya and Sierra Leone is already secured. UK piping systems manufacturer Polypipe tells Inside Mining about the introduction of a product portfolio to the African mining industry that brings a new perspective to plastic pipework.

OLYPIPE IS A GLOBAL organisation with a British manufacturing operation recognised for delivering technical excellence. With over 20 000 product lines, Polypipe boasts the broadest range of plastic pipework systems available from a single manufacturer. From this portfolio, the product that the company believes can bring considerable benefits to the mining industry in Africa is its PE100 high-pressure polyethylene (PE) pipe system. Polypipe export sales manager Philip Wood says: “Polyethylene piping is not new to the African market in general, but we have seen some scepticism about the reliability of PE systems in an environment as challenging as mining. What we can show is that PE material is inherently suitable for a wide range of applications and well-engineered PE pipework systems can meet all the challenges and deliver a number of benefits.” Supporting this claim, Polypipe’s PE100 system has been used in some of the toughest mining environments in applications such as recirculation pipelines for heap leaching operations, solution mining, process slurry pipelines and process water, as well as for compressed air. PE is both chemical and corrosion resistant, so it performs well when handling the most aggressive materials from abrasive slurries to corrosive acids, bases and salts, making it suitable for use in tailings pipelines, mineral extraction and treatment applications. It is also ideal for the supply of potable water

to a mine, as it is resistant to both galvanic corrosion and bacterium sediment build-up, unlike steel or concrete pipes, which can be badly damaged. For above-ground applications, black PE100 systems have the additional benefit of being UV-stabilised and therefore do not need to be buried or covered as they are inherently resistant to weathering. Additionally, PE is naturally non-conductive and is therefore not at risk of electrolytic corrosion, subject to taking the correct precautions to avoid the build-up of static discharge. However, should

it be a requirement, electrically conductive systems can be produced. Due to these qualities, plus PE100’s resistance to radioactivity, the material is frequently specified for drainage and water cooling systems within nuclear power plants. Wood says: “The credentials of PE as a material are well established and its qualities offer advantages over PVC, ductile, concrete or clay. What Polypipe brings to the game – and to PE – is a world-class manufacturing capability that delivers pipework systems designed to perform to a consistently high standard. Every product we make is governed by stringent British and international standards to ensure that our systems are fit for purpose and capable of being easily assembled and installed to ensure that the performance

“PE material is inherently suitable for a wide range of applications.”

Philip Wood, export sales manager, Polypipe

INSID E M INING 1 1 /1 2 | 2013 67

PIPES & PUMPS

Polypipe boasts the broadest range of plastic pipework systems available from a single manufacturer. The product that the company believes can bring considerable benefits to the mining industry in Africa is its PE100 high-pressure polyethylene (PE) pipe system

of the system is never compromised. Leakage is, of course, a major consideration. “Typically, plastic pipes are supplied in 6 or 12 m lengths, whereas concrete pipes are usually supplied in 1 or 3 m lengths, so using plastic means that fewer joints are required along the pipeline, which not only speeds installation, but also minimises potential leakage points.” Plastic pipes are also far lighter in weight than alternative materials, making the transportation and installation process less costly and far easier – especially within

mine shafts where water pipes are frequently thinner, lighter and more robust than most ceiling-mounted. rigid materials and typically weigh 94% less An issue that modern mine operators have than their concrete equivalent. to factor into their development strategies is “We are able to use a high percentage of sustainability, which can not only influence recycled material in our production and, the mining operations themselves, but also ultimately, they are able to be recycled. Bec the choice of macause of their light w terials for infraweight, the carbon It has become essential to integrate all fo structure work. PE footprint from transspecialist environmental expertise areas and recognise that different areas of the p has the advantage portation is considenvironment interlink with each other. e of excellent enerably smaller and This understanding will ensure all issues c vironmental creconsignments can be are addressed, leading to m dentials. In fact, maximised, meaning full compliance delivery – th considerably more plastics, which that Golder Associates senior geochemist, David Love m feature among the meterage can be loaded in one shipping conmost researched into ta materials in the tainer. In fact, in terms world, have become an integral part of susof total life cycle, it has been said that plastics tainable developments. With ongoing techcan be considered as one of the most energynological innovation, they have become efficient materials,” Wood concludes.

INDEX TO ADVERTISERS 3M

Atlas Copco

JVT Vibrating Equipment

Polypipe Building Products

Kaytech

Southern Mapping

KSB Pumps & Valves

SSIS

Barloworld Equipment

Bell Equipment Co. SA

Lehating Mining

De Beers

Metso Minerals

Environmental & Process Solution

Mining Indaba

(EPS)

MineRP

Fedics Site Services

Nalco Africa

10-11

OFC

Trollope Mining Services

WorleyParsonsTWP

UMP

VBKom

Veolia Water Solutions

54-55 OBC

FLSmidth

IBC

NA-SERA

G4 Civils

OFC

NuWater

Voith

Weir Minerals

IFC

Weir Minerals

Golder Associates Africa

Paterson & Cooke

Jeffares & Green

Pilot Crushtec

68 I NS IDE M IN IN G 1 1 / 1 2 | 2 0 1 3

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Unlimited resourcefulness applied… in a world of limited resources.

Nalco has, for over 80 years, understood how energy, water and air management challenges affect your business. Our technologies and services are designed to help you use less, recycle more and reduce your environmental footprint. While simultaneously reducing operational costs. From mining to petrochemicals to manufacturing, ranging from heavy industry to food processing, we bring world-class solutions for: Water treatment, recycling and reuse Dust control Mineral recovery Emission control

Backed by over 40,000 global employees, including 1,300 research professionals, Nalco Africa combines a unique understanding of energy, water and air systems with the world’s most advanced technologies. In a world of limited resources, we’re applying unlimited resourcefulness to help make the world cleaner, safer and healthier for everybody.

Nalco Africa Operations Building 14, Ground Floor, Greenstone Hill Ofﬁce Park Emerald Boulevard, Greenstone Hill, South Africa Tel: +27 10 590 9120 Fax: +27 10 590 9130 nalcoafricareception@nalco.com www.nalco.com/sa