www.miningne.ws
af r ic an u pdates on th e
g ro un d a n d un d e rg ro un d
AVK Valves
Investing in more than valves
Boikarabelo Mining large coal deposits
BouNdiali
Exploration revealing great possibilities
Exxaro
Changes making the difference
ISSN 1999-8872 • R50.00 (incl. VAT) • Vol. 09 • No. 10 • October 2016
Premset MV switchgear
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www.schneider-electric.co.za
contents
afr ic an up dates on the g round a nd underg round
08
22
Showing off mechanical and MARKET NEWS BHS AeroMaXX technology for turbo parallel-shaft gear units reduces power loss and oil consumption by 30%.
32 Editor’s Comment 3
One more chance
Mine water & wastewater management
Cover Story
25
Nitrate contamination in mine water
4
26
Using tailings for brickmaking
Africa Round-up
28
Variety of analytical solutions
6
Legal
Electrical Instrumentation & control
8
29
Investing in more than valves
News from around the continent
Safety first, zero tolerance
OCTOBER
2016
ON THE COVER p4 www.miningne.ws
Upgrading trolley assist technology AFR IC AN UPDATES ON THE
Commodity: Coal & Uranium 10
Mining large deposits in Waterberg
12
Changes making the difference
transformers
32
Processing fine and ultra-fine coal
14
35
Trip down memory lane
Comminution
36
Ensuring the quality of raw materials
16
Defining mineral sizers
Industry News
18
In-pit crushing, sizing and conveying
39 The latest news from the African
21
Fundamentals of rock breakers
mining industry
Pipes, pumps & valves
Events
22
40
The science of pumps and pumping
AVK Valves
Investing in more than valves
Minerals Processing
Focus on Africa: Ivory Coast Exploration revealing great possibilities
GROUND AND UNDERGROUND
31 Importance of maintaining
Open mining conversations
BOIKARABELO Mining large coal deposits
BOUNDIALI
Exploration revealing great possibilities
EXXARO
Changes making the difference
ISSN 1999-8872 • R50.00 (incl. VAT) • Vol. 09 • No. 10 • October 2016
AVK Holdings Southern Africa just invested R200 million in a new manufacturing plant and training centre in South Africa.
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Endorsed by In sid e M in in g 1 0 | 2016
1
UNEARTH
your brand’s potential using our print and digital solutions
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• Digimags • Newsletters • Website page views • Social media
Inside Mining, www.miningne.ws and the newsletter feature topical information on mining, exploration and minerals processing with a special focus on the mining value chain. Our readers are key decision-makers in the industry. Advertise with us and boost your products and services by receiving multi-platform exposure to your target market.
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editor's comment
Publisher Elizabeth Shorten Editor Mientjie Kleinhans Journalist Phila Mzamo Head of design Beren Bauermeister Designer Ramon Chinian Chief sub-editor Tristan Snijders Sub-editor Morgan Carter Contributors Casper Booyse, Johan de Korte, Jim Jones, Hugo Pienaar, Elizabeth Sonnekus, Dave Thompson, Ian Venter, Martin Vorster Client services & production manager Antois-Leigh Botma Production coordinator Jacqueline Modise Marketing manager Mpinane Senkhane Financial manager Andrew Lobban Administration Tonya Hebenton Distribution manager Nomsa Masina Distribution coordinator Asha Pursotham
One more chance October brings with it a sort of reality check. It marks the start of the last quarter of the calendar year, leaving just three months to finalise projects and bring ideas to fruition.
I
t also offers one more opportunity to change things around this year. The recent mining slump hasn’t been all bad
– it has offered mining companies the opportunity to do things differently.
Printers United Litho Johannesburg
Now, with mining seemingly on the
Tel: +27 (0)11 402 0571 ___________________________________
rebound – with an 11.8% growth rate in
Advertising Sales
mining and quarrying for Q2 2016 – it’s hoped that the industry will continue
Annemarie Prins Tel: +27 (0)11 233 2600 annemarie@3smedia.co.za ___________________________________
its upwards trend, buoyed by recent lessons learned. One such company that decided to
No. 9 3rd Avenue, Rivonia 2191
do things differently is Exxaro. Due to the
PO Box 92026, Norwood 2117
growth of the company and the effects
Tel: +27 (0)11 233 2600
of the mining slump, its management
Fax: +27 (0)11 234 7274/5
team realised that business is about
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more than ticking boxes in order to
Annual subscription:
South Africa: R550.00 (incl vat & postage) African countries: US$80
comply with legislation and regulations. By introducing new practices, the company was able to save 20% in costs through effective risk management and
Foreign: US$100
better resource allocations. Read more
Email: subs@3smedia.co.za
on page 12.
ISSN 1999-8872 Inside Mining Copyright 2016. All rights reserved. ___________________________________ All material in Inside Mining is copyright protected and may not be reproduced either in whole or in part without the prior written permission of the publisher. The views of contributors do not necessarily reflect those of the publishers.
It is no secret that the next big region for coal mining is in the Waterberg. Inside Mining takes a look at the new Boikarabelo Project – an open-cut surface mine, which will start full production in Q1 2019. It will be a longterm project, with an expected life of mine of 70 years, possibly extending up to 200 years.
To our avid readers, be sure to sign up and get the latest updates and inside scoops from the mining industry. Check out what we are talking about on our website and Facebook page, or follow us on Twitter and have your say.
@mining_news www.facebook.com/pages/ Mining-News
Read how the mine is claimed to be the most advanced new mine in the Waterberg on page 10. A greenfield project that is still at the beginning of the exploration process is the Boundiali Project by Predictive Discovery in the Ivory Coast. This recent discovery of gold employed modern geochemical methods and the early exploration results indicate encouraging surveys. Read more about this fascinating project, which has no people living on or near the site, on page 14. If you’re more interested in mechanical matters, veteran Jim Jones, who has been in the pumping industry for more than 50 years, takes a look at pumps and explains how pumps are measured, and more. Inside Mining also looks at how mineral sizers compare to double-roll crushers, and how they work. Further, in-pit crushing and sizing and in-pit crushing and conveying are compared to the economics of truck haulage of material. To ensure that future generations are aware of current and historic coal processing methods, the Southern African Coal Processing Society is assisting the Geology Museum in Johannesburg with the set-up of a display. There will also be other, nondisplay items available to researchers. To augment the display, the curator of the museum requires donations of any objects related to coal mining. Read more about this initiative on page 35.
Mientjie Kleinhans FOLLOW THE LINK For updated news: www.miningne.ws
In sid e M in in g 1 0 | 2016
3
cover story
Investing in more than valves Investing R200 million in a new plant and complying with the DTi’s local content rules are testament that AVK Holdings Southern Africa believes in the country. The company combines this with the true passion of the employees to offer unique product solutions.
T
HE DEPARTMENT of Trade and
Complying with the rules means that
weeks, or manufacture according to
Industry’s (DTi) designation rules
the company is proudly South African; it
specifications. “This means that compa-
stipulate that state-owned entities
manufactures in South Africa and exports
nies don’t have to wait for their products
must procure locally manufac-
to other countries, and can assist with job
to be shipped from overseas, which
tured products with 70% local content.
creation and transfer of skills. “Apart from
could take anything between 10 weeks -
AVK Holdings Southern Africa realised
the 70% local designation, 40% needs
24 weeks. It also excludes various shipping
what that would mean for the local
to come from SMMEs. Therefore, we are
problems such as storms at sea, or cus-
economy and took the lead in complying
making use of many SMMEs to assist us
toms clearance issues,” explains Kloppers.
with the designation rules, even though
in the manufacturing process of various
they are not yet compulsory.
components,” says Kloppers.
“When considering the new mining
during the manufacturing process, or
charter that is coming out soon, local
R200 million plant
designation and local manufacturing are
Kloppers is very excited about the new
“Normally, companies would have to get
going to play a key part in the future of
manufacturing plant in Alrode, Johannes-
international employees or international
the mining charter. Together with all the
burg. The new facility includes a
branches to inspect the goods prior to
other important aspects like BBBEE, which
1 200 m training facility, 2 500 m office
is also changing with the new scoring
area and 2 000 m2 logistics and ware-
2
prior to delivery to their plants and sites.
2
leaving the factory. “This offers peace of mind with the
systems, it made sense for the company
house space. With the new manufactur-
products being manufactured local-
to comply with the rules,” says Riaan
ing plant in South Africa, the company
ly, which is unique to our company,”
Kloppers, manager: Industrial Division,
can either supply directly off the factory
says Kloppers. The company also involves
AVK Valves Southern Africa.
floor and save companies six to eight
the mining industry with its research and
The new AVK manufacturing plant in Alrode, South Africa
4
He adds that South African companies can now inspect the ordered goods
Ins i de Mi n i n g 1 0 | 2 0 1 6
cover story development (R&D) in developing different types of products specific to local conditions. Kloppers says that the company does just about everything in-house regarding the R&D, which means having a local manufacturer that can assist with extra development. “When mines want to introduce new technology, they can join us while we design or manufacture products for them. We can also install it for them and they can give us their feedback; it is a total value-add.” Kloppers adds that many AVK products
Left to right: Lars Kudsk, Tjaart Van der Walt, Paul Hubbard, Trine Rask Thygesen, Malebo Mabitje Thompson, Niels A Kjaer, Peter Thomson and Brian McGugan
in the meaning of cost of ownership. Our products might be 2% more expensive, but they will save an immense amount of money in installation and reduced downtime. We offer products that last
are unique to the South African market. “All the patented products specific to
valve-related products globally. “We
for the lifetime that the plant was initially
South Africa that used to be manufac-
obviously looked at which products are
designed on,” claims Kloppers.
tured elsewhere in the world will now be
in high demand in Southern Africa and
manufactured locally.”
will manufacture those in huge quantities.
Training centre
These include products with SABS certifi-
The company identified a need for train-
cations, and products for
ing in the market. First and foremost, the
specific contracts.
new training centre will assist with skills
New technologies The new plant includes a brand-new, state-of-the-art powder-coating plant that is unique to South Africa. The new
“We will also manufacture gate valves, resilient seated valves, valves used for
transfer and will offer a variety of courses, from beginner to more advanced
testing equipment as
drilling shafts and valves
programmes. The idea is to keep it neu-
well as the new num-
used to find water
tral and generic. Kloppers explains that
pockets or gas pockets.
new engineers, as well as people who
Furthermore, we man-
order products, need to understand the
ufacture gas detection
different valves available. “For instance,
systems for different
we struggle to get the correct informa-
types of applications
tion from clients ordering valves. With
and ball valves for the
the training centre, we assist the market
nuclear industry. We are
by laying out the foundation from a nov-
bering system, with full traceability, are new technologies as well. “We have a fool-proof system in place to eliminate the human
Companies don’t have to wait for their products to be shipped from overseas
error that one normally finds in a manufacturing plant, thereby
currently reviving the entire range of IPV
reducing possible delays,” says Kloppers.
valves, which are used in harsher types of
Products
applications,” says Kloppers. He adds that another unique aspect
ice person to engineers.” The training centre will look at various topics and courses such as plant evaluations, to identify three elements that
Every single one of AVK’s products has
to the company is that the majority of its
could prolong the life of valves by at
some or other unique patented feature,
products are maintenance-free. Where
least five to ten times, namely:
according to Kloppers. AVK manufac-
maintenance is required, it is a simple,
• Are the valves installed in
tures just over 60 000 different valves and
fast procedure where one doesn’t have to drain the entire system. The replacement of the product might take up to 10 or 15 minutes, before restarting the process and resuming production. This adds up to a product with unique tech-
the correct position? • Is it the right valve for the specific application? • Is the valve manufactured for the material passing through?
nologies that can save the end user time,
Conclusion
money, and effort. “We believe strongly
Kloppers explains that the company sees itself expanding even more in South Afri-
Malebo Mabitje Thompson, deputy director general of the Department of Trade and Industry, and Niels A Kjaer, owner of AVK Holdings A/S, at the opening of the new premises
ca. “We still have about R250 million on the cards to invest in South Africa, specifically regarding new technology.”
www.avkvalves.co.za
In sid e M in in g 1 0 | 2016
5
Mining news
from around the continent Burkina Faso Gold rush prompted by high deposits
busy with the feasibility study of the mine, to make sure the mine is still viable; this obviously needs money. Up until now, the number of illegal miners has gone from several hundred into the thousands, and we have asked the government to reinstate the security they had previously assisted with to try and rectify the situation. “We’ve had to withdraw all non-critical workers on the mine, and leave those who are providing critical services to the mine and the community at large, because it is now a safety issue, but there has been limited intervention by government,” he continued.
IVORY COAST
Processing facilities at the Essakane Mine in Burkina Faso
BURKINA FASO
Mining exchange for exploration and operation West Africa’s regional stock exchange – the Bourse Regionale des Valeurs Mobilieres (BRVM) – plans to start a
on the mining company’s production or
separate section for mining stocks and
costs, as the mine wasn’t forecast to be
have a dedicated mining platform in
operating this year, but the prolonged
place by 2018, general manager Edoh
The West African nation of Burkina Faso
occupation of illegal miners on the
Kossi Amenounve said in an interview.
has increased its gold output by more
mine threatens the long-term viability
than 20 times in the last decade. In a
of the mine. In February, the military
for resources companies to raise funds
review of its geological records, it was
protection unit that was posted on the
in the local Communauté financière
noted that the country has more gold
mine withdrew its protection, leaving
d’Afrique franc currency, the head of the
waiting to be discovered.
the mine vulnerable, and it was overrun
BRVM said. The mining exchange will be
by illegal miners.
open for companies exploring or operat-
High gold deposits prompt rush
Mining Minister Alfa Omar Dissa said, in
The move is aimed at making it easier
an interview, that the government wants
Steward Bailey, senior vice-president:
to help companies that are already op-
Investor Relations & Group Communica-
The BRVM is in talks with the Toronto
erating in the African nation to lengthen
tions, AngloGold Ashanti, said, “The mine
Stock Exchange to set up a “technical
the lives of their mines and make it eas-
was placed on care and maintenance.
partnership” between the two bourses
ier for new investors to get information
We had the intention of modernising the
inspired by the Canadian mining-ex-
about deposits.
mine in order to convert it. We were also
change model. “Mining companies
ing mines in the region, he added.
“We’ve reviewed the eastern, western and southern regions, and we found some very interesting information,” he said. Deposits previously unknown include gold, lithium, nickel, a bit of uranium, and even traces of oil. The country has seen a gold rush in recent years because of the high grades found in some deposits, which hold as much as 17 grams per tonne, compared with the global average of 1.5 grams per tonne, Dissa explained.
GHANA
Tightened security hoped to repel illegal miners Disruptions by illegal miners at AngloGold’s Obuasi mine have not impacted
6
Ins i de Mi ni ng 1 0 | 2 0 1 6
Ghana Locked gates to keep illegal miners out
SOUTH AFRICA
Edoh Kossi Amenounve, general manager, Bourse Regionale des Valeurs Mobilieres
Survey suggests executives investing in technology A survey reflected in KPMG International’s 2016 Global Metals & Mining Outlook noted that less than half of the executives responding depicted low levels of confidence in the prospects of the global economy over the next
The future of mining lies in advanced technology and robotics
two years, albeit the tight relationship operating in the region only raise funds in
between the fortunes of the global econ-
different than in the past, particularly
foreign currencies,” the GM said. “Some
omy and that of the global metals and
given the structural changes taking place
of them have approached us to see how
mining industry.
and the environmental regulations cur-
they could raise the resources they need in local currency.
The KPMG survey taken by senior metals
rently being tabled around the world.”
executives suggests that most metals ex-
To alleviate the tensions in the market,
Some have even asked us for a dual
ecutives are confident that there will be
tapping into technology is one aid they
listing with the Toronto stock exchange,
growth in the next two years, citing two
intend on using. The survey shows that
but the regulating framework isn’t com-
main strategies – growing their existing
metals executives plan to channel signifi-
patible at the moment.” Companies
market share and entering into new mar-
cant investment towards developing and
that want to sell shares on the bourse are
kets. Jacques Erasmus, global head: Min-
implementing new manufacturing tech-
currently required to provide certified
ing, KPMG, says, “When growth does re-
nologies aimed at driving efficiency and
accounts for at least two years.
turn, the market will likely be significantly
improving performance.
In sid e M in in g 1 0 | 2016
7
legal
Safety first, zero tolerance Mines have implemented a variety of policies and procedures to keep workers as safe as possible. One such preventative measure is testing for alcohol at the security entrances of mines. By Hugo Pienaar and Elizabeth Sonnekus, Cliffe Dekker Hofmeyr
Y
ET, WITH ALL these precau-
Act (No. 66 of 1995) (LRA) recognises
tions in place, people under
misconduct by an employee as a fair
the influence of alcohol are
reason for dismissal.
found on-site during working
the employee is under the influence of
ger, whether they are driving heavy ve-
Two scenarios in which an employee may be charged for alcohol use at the workplace
hicles or operating potentially danger-
In the first scenario, the employee’s
to work has been impaired.
ous machinery. Even if people under
drunkenness can be proven by sight,
the influence are just walking on-site, it
smell and/or the conduct of the em-
that a positive test result is sufficient
can put their lives in danger.
ployee. Aggressive behaviour from
proof to charge the employee for be-
the employee, slurred speech and
ing under the influence of alcohol.
hours. These people place their lives and those of their colleagues in dan-
Due to all the policies and proce-
alcohol or that the employee’s ability Employers often mistakenly believe
dures in place, one would expect that
bloodshot eyes are some of the factors
people under the influence at work
indicating drunkenness. The degree
a positive test result is not necessarily
could be dismissed immediately. This
of drunkenness has to be to such an
sufficient to dismiss an employee. In
has been proven not to be the case.
extent that it impairs the employee’s
Tosca Labs v CCMA 2012 33 ILJ 1738
Often, employers are under the im-
ability to work. The onus is on the em-
(LC), the Labour Court found that a
pression that when an employee tests
ployer to prove this. No expert witness
positive test result on a breathalyser
positive for alcohol, the person is ac-
is required for such purposes.
test is not sufficient proof to indicate
tually under the influence of alcohol.
8
People under the influence of alcohol are a potential safety hazard to co-workers and machinery
The second scenario is where an em-
Recent case law has confirmed that
that the employee was under the
Alcohol and drug abuse is a form of
ployee tests positive for alcohol on a
influence of alcohol. The court
misconduct. Schedule 8 of the Code of
breathalyser apparatus. A positive out-
referred to Tanker Services (Pty) Ltd v
Good Practice of the Labour Relations
come does not necessarily prove that
Magudulela 1997 12 BLLR 1552 (LAC),
Ins i de Mi n i n g 1 0 | 2 0 1 6
legal which stated that the real test is
summarily dismissed irrespective of
whether the employee’s competence
whether his/her ability to work is im-
to perform their work has been
paired or not. To adopt such a policy
impaired. In this case, the employee
depends on the status thereof, and
was able to perform his tasks and the
may sometimes simply require consult-
court held that the dismissal was substantively unfair.
What should an employer do? The employer should adopt a zero-tolerance
ing with the employees be-
The degree of drunkenness has to be to such an extent that it impairs the employee’s ability to work
policy in terms of
fore its implementation. The employer should always ensure that all employees are aware that there is a zero-tolerance policy, and that if they test positive for any usage of alcohol, they will be in breach of the policy and
alcohol in the workplace. Such a
may be subjected to disciplinary ac-
policy should be specific and also
tion and possible dismissal.
provide for a summary dismissal, even
In addition to the above, the breath-
when the employee has only been
alyser apparatus should be properly
tested positive for the use of alcohol
calibrated and the person administer-
or drugs. The rationale for such a policy should be based on the safety considerations of the employer. This means that an employee may be
People under the influence of alcohol can create a danger on-site, regardless of what they may be doing preferably be obtained to show that the employee’s ability to work was impaired – if that was indeed the case. If it emerges that an employee is
ing the test should be trained to do so
dependent on alcohol, the employer
correctly. The test should also always
has an obligation to consider
be done in the presence of a witness.
providing counselling and assisting
However, where possible and applicable, evidence should
the employee as set out in item 10 of Schedule 8 of the LRA.
In sid e M in in g 1 0 | 2016
9
Commodity: Coal & Uranium
Mining large deposits in Waterberg T
HE BOIKARABELO Coal Project
Sedgman has a strong track record in
more consistent and will increase our
will be a long-term project with
terms of design and construction, and
yield,” explains Van der Bank.
an expected 70-year life of mine,
coal handling, as well as a strong bal-
with a possibility to extend up to
The washing plant has a 2 100 t/h duel-
ance sheet. The second strategy that
integrated module design (each unit
200 years. This is unsurprising, taking into
the company adopted to save costs is to
with with a 1 050 t/h capacity) with a
consideration that the Boikarabelo coal
base contracts on fixed-price lump sums.
two-stage concept: high-cut/low-cut
seam is between 120 m and 130 m thick,
“In other words, the EPC undertakes
and between 20 m and 30 m below the
to provide the services for a fixed price.
both a high-grade product and a
surface. The zones contain varying quali-
Any cost overrun will be for their ac-
secondary lower-grade product.
ty thermal and soft coking coal.
count, rather than ours. The benefit of
Resource Generation (ResGen)
implementing these two aspects is that
acquired 16 000 hectares of land in
the risk is now moved from our balance
the Waterberg and reported probable
sheet to the balance sheet of the con-
reserves of 744.8 million tonnes of coal on
tractor,” says Lowe.
35% of the tenements. Mobilisation of the processing plant
Processing plant
construction crew will occur from January
Zirk van der Bank, COO, ResGen, explains
2017 and the plant should be commis-
that the processing plant will process
sioned from July 2018 and operational by
2 100 t/h (tonnes per hour), starting off
the end of Q4 2018. The open-cut surface
with 700 tonnes run of mine ore. From
mine will start full production Q1 2019.
there, the material will go to the crushing circuit that has a capacity to process
Contractor
2 500 t/h.
To ensure that the mine yields the best
“The three-stage size reduction system
results at the lowest possible cost, Res-
crushes ore down from 1 000 mm to
Gen adopted a new execution strategy,
50 mm. The first stage is beneath the run
based on using a limited number of en-
of mine bin that crushes the material to
gineering procurement and construction
300 mm, followed by duel slow-speed
(EPC) contractors with a good track re-
roll sliders that will reduce the material
cord and a strong balance sheet. They will also have the right to recall a contract in case of failure or delay. “With these requirements in mind, we went
The project is located 40 km from an existing rail system, which will mean access to the ports of Maputo, Richards Bay and Durban
into an agree-
10
Waterberg is said to be the next coal resource in South Africa, with approximately 40% of the country’s remaining coal reserves. This is exactly where ASX- and JSE-listed, South Africa-based company Resource Generation has started to develop the Boikarabelo Project. By Mientjie Kleinhans
down to 50 mm,” explains Van der Bank. From the run of mine and crushing circuit, the coal will go on to the run of mine stockpile facility with a 150 000 tonne capacity. A coal linear stacker with
ment with Sedgman Limited, a member
a full-face-bridge-type bucket wheel
of the CIMIC Group, for a fixed lump
reclaimer ensures that it fully blends the
sum contract of US$141 million, subject
stacked raw coal for smooth feeding
to exchange rate fluctuations,” says
into the coal processing plant. “This is
Rob Lowe, CEO, ResGen. He adds that
to make the raw coal plant feed much
Ins i de Mi n i n g 1 0 | 2 0 1 6
washing stage designed to produce
The entrance gate to the Boikarabelo project
Commodity: Coal & Uranium
The Boikarabelo project is located in Waterberg in Limpopo province
sustainable water resource underground that is within the mining rights area. The plant has been optimised to ensure that “The key process circuits include two-
be an open-pit mine with a strip ratio
we use the minimum amount of water,”
stage dense medium cyclones for coarse
of less than 1, which is extraordinary in
says Van der Bank.
coal processing and a two-stage reflux
mining terms.” Further to that, ResGen
classifier system for fine coal processing,”
has developed a logistics solution that is
the local municipality’s sewerage plant
says Van der Bank. The fines will be
competitive and Lowe hopes that this will
in the future for use at the mine. “There
dewatered through belt press filtration.
encourage other mines to follow suite.
are a couple of options we have re-
The project is located 40 km from an
He adds that they will treat water from
garding water, but our main source will
Unique
existing rail system, which will mean ac-
According to Lowe, the Boikarabelo
cess to the ports of Maputo, Richards
Project will be the most advanced new
Bay and Durban – opening up domestic
Energy
mine in the Waterberg. “The Waterberg
and export routes. “When we receive
The project will make use of 30 MWa
have been identified as the next viable
funding, we will proceed to develop the
power from Eskom and the substation
coal reserve for South Africa. We see
railway link,” says Lowe.
has been constructed. “That will pro-
ourselves as the key that will unlock
be underground water.”
vide sufficient electricity to the mine.
the Waterberg and an essential part
Water management
of SIP1, which is unlocking the northern
A detailed water management plant
day now, which will be in time for when
mineral belt with Waterberg as the cat-
has been developed for the water man-
construction commences,” concludes
alyst. Adding to that, Boikarabelo will
agement on the project. “We have a
Van der Bank.
Eskom will connect to our system any
In sid e M in in g 1 0 | 2016
11
Commodity: Coal & Uranium
Changes making the difference
A combination of tough economic times and a strategic realignment required Exxaro to change its governance, risk and compliance (GRC) management system. These changes brought about cost savings through effective risk management and better resource allocation. By Mientjie Kleinhans
A
S THE SECOND LARGEST coal
challenging themselves to as to why it is in
producer in South Africa, Exxa-
the Act itself. “For example, if one looks at
ro implemented a new strate-
the Act, it assists in creating a safe work-
gy that goes beyond the the-
ing environment. Instead of looking at the
ory and tick-box approach, moving staff
objective of a safe working environment,
approach, and is expanding on to a
to understand GRC management and ask
people are walking around with check-
sixth capital, namely intellectual capital.
why things are done in a specific way.
lists and doing inspections because they
The other five are:
“What I have seen, in general, is that min-
think it is going to create a safe working
• natural capital
ing companies often introduce a GRC
environment. But, instead, they are simply
• human capital
system for compliance’s sake. It is as if
proving that they comply with the differ-
• social capital
they are losing the practical perspective
ent laws and regulations,” explains Van
• manufactured capital
because they are so inundated with var-
Loggerenberg.
• financial capital. “With this inclusion, we have done well
ious laws and regulations they need to
The same applies to risk management
comply with that they tend to forget to
at an operational level. By really under-
by marrying our sustainability goals
consider why they need to comply with
standing the reasons of the Act and
with the overall company goals. We no
the different pieces of legislation. This is
complying therewith, the Act will help
longer talk about the sustainability goals
especially the case in the operations en-
businesses achieve their objectives,
separate to the general company goals
vironment with regard to complying with
of which one is safety. Simply asking
– something that companies did wrong
the Mine Health and Safety Act
why the company has to comply will
in the past,” explains Van Loggerenberg.
(No. 29 of 1996). People need to under-
change the perspective on compliance
stand why they should be doing certain
risk management.
tasks,” says Saret van Loggerenberg,
12
Dust management has been elevated to a higher risk level due to especially dry conditions in South Africa
A successful solution lies in marrying the GRC system to what the company wants to achieve in business, and over-
manager: Risk & Compliance, Exxaro. She
Sustainability goals
laying that with the overall strategy. “For
explains that people often have a strin-
Exxaro introduced the five capitals
us, it was really all about identifying the
gent tick-box approach, without really
model as part of its triple bottom-line
overall GRC approach and then looking
Ins i de Mi n i n g 1 0 | 2 0 1 6
Commodity: Coal & Uranium
dust risk at one level, and challenge the strategic risk at the very top. This means explaining to people how to adopt
Effective risk management and better resource allocation brought about cost savings for Exxaro
the same risk management process at different layers of the organisation,
extracting water, and the quality of
replicated in different layers but for
water that is discharged again. Mines
different purposes.
need to be cognisant of the water
“People now need to understand that
less with their water usage, lest they
apply it to different objectives. You can
exacerbate the problem.”
apply the same process in different are-
Saret van Loggerenberg, manager: Risk & Compliance, Exxaro
availability challenges and not be reck-
they must follow the same logic, but just
as, such as technology, engineering and
Challenges
mining, by using different sets of facts,”
Van Loggerenberg says that another
says Van Loggerenberg.
challenge Exxaro is facing is to alter its
The same goes for another cru-
compliance-driven tick-box approach
cial element of water conservation
to accommodate changes to the sus-
and management.
tainable business objectives; one of
Van Loggerenberg explains that, generally, businesses should employ a
which is operational safety. “The other challenge that I have seen
strategy that aligns with their objectives
is that people are operating in silos
at how the business can support that. I
while also ensuring sustainability. “The
and there is not much cross-functional
think, if one does that, then much of the
reason for this is that most companies
collaboration happening within the
gap can be filled with business imple-
believe in GRC and in being sustainable,
company – especially concerning safe-
mentation and negotiation.
but it often stops at
“It is also important to understand
the strategic level,
ty. Some people think
“We have done well by marrying our sustainability goals with the overall company goals.”
that safety is solely safety
the culture of the organisation that
and sustainable KPIs
one works in to ensure that the systems
are never pushed
support the goals in terms of thought or
through to the oper-
compliance management processes. It
ation. They will pro-
is really critical to understand the goal
vide the necessary
you are chasing and then to implement
measures on these
a system that mirrors that. It is all about
things, but they
adjusting the system to suit the compa-
don’t always know
Loggerenberg.
ny’s needs,” says Van Loggerenberg.
why they have
She believes that anoth-
specialists’ problem, so they push that obligation away from themselves and their respective departments. Everybody should become proactive,” says Van
measures on the sustainable KPIs.” She
er challenge is the reluctance to adapt
adds that the sustainability KPIs are used
and enhance technology to achieve
One of the risk areas recently discussed
to improve social licence to operate.
an integrated proactive approach –
within the company is dust manage-
For this reason, it is essential that they be
to change behaviours and traditional
ment, which has been elevated to a
measured, although companies are not
ways of thought.
higher level due to the dry season that
being told why they are measured.
Dust management
South Africa has been experiencing late-
“To me, it is more of an add-on to
“We still have a long way to go there, but at least we have started. We have
ly. Another focus area for the company
the operations’ objectives. With water
a very proactive CEO in Mxolisi Mgojo,
is integration and, with the integrated
being a definite challenge, we are
who believes that we need to change
system process, the company uses the
carefully monitoring our water perfor-
the way we do business,” concludes
same process to unpack elements of the
mance and how people are using and
Van Loggerenberg.
In sid e M in in g 1 0 | 2016
13
Focus on Africa: Ivory Coast
Exploration revealing great possibilities Using modern geochemical methods, new gold resources have been discovered and explored in the Ivory Coast. Mientjie Kleinhans finds out what makes Predictive Discovery’s Boundiali Project so interesting, besides being located in a favourable gold mining investment destination.
A
S A GREENFIELD development
suggest that the gold mineralised system
“This new set of results confirms that the
without pre-existing artisanal
persists over most of that length, suggest-
newly discovered Nyangboue gold
miners or people living on
ing the potential for large tonnages of
mineralised system persists both at
or near the site, with initial
gold mineralisation.
depth and along strike. We are espe-
drill results indicating visible gold in the
cially encouraged by the high grade of
higher-grade sections, the project is truly
so far are in the unweathered zone,
the first of the deepened holes on the
worth investing in.
which suggests that there is potential for
first section drilled, possibly indicating
mineable grades to substantial depth,”
an additional mineralised zone. These
explains Roberts.
new assays tell us that the gold system
“The project is still at the beginning of the exploration process and we have received results from only two of the eight
extends at least 320 m to the next line
drill lines. In the event that we define a
Drill results
potential gold deposit and after com-
The latest drill highlights from Boundiali’s
sults covering a 2 km strike length yet to
pletion of a definitive feasibility study, a
Nyangboue prospect include:
come,” says Roberts.
decision to start a mine would be some
• 9 m at 7.9 g/t gold from 99 m,
years in the making,” says Paul Roberts, managing director, Predictive Discovery. He explains that initial drilled gold
including 1 m at 44.7 g/t gold
to the north, with the majority of drill re-
He adds that the assay results have been returned a little more slowly than
• 7 m at 3.8 g/t gold from 33 m,
hoped, due to some delays at the ana-
including 1 m at 11.3 g/t gold
lytical laboratory. “We now expect that
grades and widths are both very impres-
• 8 m at 1.5 g/t gold from 38 m
the rest of the results will arrive soon. We
sive and the gold value starts from the
• 9 m at 1.2 g/t gold from 20 m.
will release these assays as soon as they
surface. “There is visible gold in the high-
The multiple mineralised zones on the
come to hand.”
grade sections, suggesting that the gold
second drill line, 320 m north of the first,
is unlikely to be refractory and may be
indicate that the mineralised package
mit is located within a very well mineral-
partly, or even largely, treatable by rela-
extends for at least 320 m along strike,
ised greenstone belt. “This area contains
tively low-cost gravity methods.”
and is open to the north and south and
the two gold mines in the Ivory Coast
at depth, according to the latest results
and Mali, namely Tongon and Syama.
interesting is that the coherent gold-
report. To get the results, 92 holes were
There has been little exploration in this
in-soil geochemical anomaly is large
drilled, totalling 5 496 m. Six drill sections
area and, hopefully, there will be more
– 2 km long – and the more recent results
with 69 holes are still outstanding.
gold to be discovered.”
What makes the project even more
The exploration team at work on-site
14
“The highest-grade intercepts obtained
Ins i de Mi n i n g 1 0 | 2 0 1 6
Roberts explains that the Boundiali per-
RELIABLE SIZER PERFORMANCE In 1978 we developed and introduced the Twin Shaft MINERAL SIZER™ to help underground coal mines break coal more efficiently and effectively whilst also increasing productivity. Today we have progressed the Twin Shaft MINERAL SIZER™ to provide a unique range of trusted solutions and systems for both underground and open pit mining operations. With over 3000 installations worldwide, MMD have the knowledge and expertise to deliver reliable systems that maximise production, improve safety and increase efficiency. MMD remains a group of committed and experienced professionals who have the skills and knowledge to provide reliable after-sales service and technical support via a network of local offices.
+27 11 608 4801
sizers@mmdafrica.co.za
For more information please visit WWW.MMDSIZERS.COM
COMMINUTION
Defining mineral sizers Understanding what defines the MMD Twin Shaft Mineral Sizer, how it compares to a double-roll crusher, and the role it plays in comminution, can make all the difference. Martin Vorster* discusses the role of mineral sizers in comminution.
A
LTHOUGH MINERAL sizers are
are the three-stage breaking action,
These subject the rock to multiple-point
manufactured in various
the rotating screen effect, and the
loading, inducing stress into the material
sizes, the principle remains
deep-scroll tooth pattern.” Mineral sizers
to exploit any natural weakness and
the same. The definition of a
exploit the already inherent weakness in
fracture planes – fundamentally utilising
mineral sizer is best described by MMD
rocks. The patented tooth geometry and
tensile rather than compressive forces to
Mineral Sizing (Africa): “The basic con-
configuration subjects the material to
break material.
cept of the MMD sizer is the use of two
stress, bending, tension and shear forces
rotors with large teeth, on small-diameter
in an effective and quick three-stage
Stage 2
shafts, driven at a low speed by a direct,
breaking action.
At the second stage, material is broken
high-torque drive system. This design
in tension by being subjected to three-
produces three major principles that all
Stage 1
interact when breaking materials using
Initially, the material is gripped by the
tooth faces on one rotor and rear tooth
sizer technology. The unique principles
leading faces of opposed rotor teeth.
faces on the other rotor.
point loading, applied between the front
A typical example of a double-roll crusher
16
Ins i de Mi n i n g 1 0 | 2 0 1 6
COMMINUTION table 1 Characteristics of good mineral sizer utilisation
Primary mineral sizer
Secondary mineral sizer
Double-roll crusher
Highest possible reduction ratio to be used
Driven toward final product size “finishing”
Ideal for tertiary crushing application where small product size is required (<30 mm)
Sizing effort a maximum at primary stage
Typically lower reduction ratios
Typically even lower reduction ratios
Larger wear components translate to extended operating throughput
“Hard work” to be done by primary sizer
Care must be taken to match feed material to nip void
Smaller wear components require more frequent changing Minimises fines generation
Stage 3
a rotating screen effect, and typically
A breaker bar, located beneath and
features large teeth on relatively small
between the twin shafts, provides a third
shafts. At the same time, it allows lower
stage of breaking in the centre of the
power demand due to scrolled engage-
machine, for maximum three-dimension-
ment. Typically, a reduction ratio of ~5:1
al control of the finished product size.
and above can be achieved. A mineral
Deep-scroll tooth pattern The deep-scroll pattern conveys larger
sizer can be designed for primary, secondary or tertiary sizing applications. A double-roll crusher has the potential
material to one end of the machine
for “slabby” product to pass through the
and distributes the feed of raw material
machine, due to the parallel-teeth ar-
along the length of the rotors. This unique
rangement. With the double-roll crusher,
action offers a large reduction in energy
fines generation becomes an issue if the
requirements to size material when com-
material feed is mismatched with the
pared with multiple-tooth engagement.
nip void, which causes a grinding effect.
The pattern also allows for the rejection
Indirectly, this results in higher wear rates.
of oversized material, if required. Without a deep-scroll pattern, the material feed must be well matched to the drum diameter or else material
The material is broken in tension by being subjected to three-point loading
There is a higher power demand due to the multiple-tooth engagement, and
Any lumps of material that still remain oversized are broken, as the rotor chops through the fixed teeth of the breaker bar
the typical reduction ratio is ~2:1.
hang-up and the grinding of oversized
Good mineral sizer utilisation
materials are likely. This causes excessive
When a mineral sizer is used in a primary
wear and fines generation, due to the
application, the highest possible reduc-
grinding action. If the material is too
tion ratio is used to get the material as
big, it will be grinded – which creates
small as possible, as quickly as possible;
unnecessary fines.
therefore, the sizing effort needs to
Furthermore, double-roll crushers
The material is gripped by the leading faces of opposed rotor teeth
be at its maximum at the first stage,
typically demand higher power con-
where a mineral sizer’s larger wear
on the application and requirements
sumption, due to increased crushing
components translate into extended
of the client. The machine’s compact
effort, with multiple-point simultaneous
operating throughput.
dimensions make it ideal for mobile in-
engagement along the rollers.
The rotating screen effect
When a mineral sizer is used in the
stallations or retrofitting in underground
secondary crushing stage, the sizer is
operations where space is limited.
geared towards final product size, or
Finally, a key design benefit is that all
A mineral sizer creates a rotating screen
“finishing”. This, typi-
effect from the interlaced rotor design
cally, allows for lower
that allows undersized material to pass
reduction ratios with
through with minimal degradation. The
minimal wear and the
continuously changing gaps around
hardest work to be
the rotor minimise fines generation and
done by the primary
reduce power consumption. In turn, this
sizer. A double-roll
means the MMD sizer negates the need
crusher is ideal for tertiary crushing ap-
ability to process wet, sticky material or
for pre-screening.
plications where a small product size, of
hard, dry rock, or a combination of the
<30 mm, is required. A double-roll crush-
two, and has proved to be the ideal
er typically offers even lower reduction
sizing solution for over 80 different
A machine is a mineral sizer when it de-
ratios. With this type of crusher, care
minerals worldwide.
livers a 3D cubical product controlled
must be taken to match feed material
in all three principal directions. The ma-
to the nip void. A full range of MMD
*Martin Vorster is the managing director
chine also minimises fines generation via
mineral sizers is available, depending
of MMD Mineral Sizing (Africa).
Characteristics
the breaking forces
A machine is not a sizer if it does not scroll the material
are fully contained within the frame, requiring minimal support structure. MMD’s Twin Shaft Mineral Sizer has the
In sid e M in in g 1 0 | 2016
17
COMMINUTION
In-pit crushing,
sizing and conveying In-pit crushing and sizing (IPCS) and in-pit crushing and conveying (IPCC) are not new technologies, yet applications thereof should be seriously reconsidered in these challenging financial times. The potential savings can be significant. By Dave Thompson*
T
he majority of development of coal in South Africa, over the last
poor hauling conditions.
Benefits The benefits of an IPCC/IPCS system
century, has been in the Emalahl-
All of the above options require roads,
surpass the initial layout costs in the long
eni and Middelburg areas in the
but in the soft rock mining industry, we
run, as it increases the run of mine pro-
Mpumalanga province. Now, all eyes
tend to fall flat. We end up having large,
duction by between 10% and 20%. It can
are on the Waterberg region as the next
heavy trucks travelling on poor roads,
also increase the plant yield, as the coal
potential coal fields to expand to. This
which damages the trucks. We get nei-
fed into the plant is void of rubbish. This,
region will predominantly be opencast
ther the availabilities nor the productiv-
in turn, means less maintenance costs,
mining due to the shallow line of coal
ities – all because we are mining a bulk
with less wear and tear due to the ab-
in the area.
commodity and the bulk is crucial to
sence of hard material.
When considering new mines, it is important to consider the crucial design
keeping the costs down. Further than having
stages of any project and to keep inno-
to build and maintain
vation in mind. Obviously, capital, oper-
roads, the trucks are driv-
ations, services and marketing are key
ing up costs due to:
drivers to any business venture.
• high maintenance and
Challenges The challenges that are all very pertinent
repair costs • poor road-building practices
to the coal mining industry at the mo-
• poor safety records
ment include:
• regulatory constraints
• low commodity prices • increasing strip ratios
There are quite a few
An IPCC/IPCS system discards the rock and mud stones, sending only products to the processing plant
options to consider over big trucks hauling material between the pits and the processing plant. A truck is an inefficient mode of transport. Implementation of in-pit crushing and conveying, or in-pit crushing, sizing and conveying is not a new concept. A
now being imposed that make operat-
semi-mobile IPCC/IPCS system brings the
ing trucks even more costly
run of mine closer to the working phases,
• decreasing saleable product yields
• long haul routes
and, therefore, half the number of trucks
• global demand for cleaner energy
• poor equipment utilisation.
are required for the operation.
• pressure to reduce carbon footprints
The question that keeps coming up is
• project financing challenges
why do we want to take low-quality run
cient method to remove the run of mine
• high costs of labour
of mine feeds, which have mud stone
product or overburden in a more cost-ef-
• productivity challenges.
bands and sand stone bands, all the
fective way.
With that, the current open-pit mining
way to a centralised crushing facility
method options include:
to remove all the waste material and
of the truck is always going to be 50% to
• draglines, which have high capital cost
upgrade them there, and then have to
55% of the load. A point to consider is all
bring all the waste material back to the
the energy spent to move the 50 tonne
in-pit regions to backfill and rehabilitate?
to 200 tonne per unit truck around, even
This is especially pertinent when one
when it is empty. Then, it gets loaded
could quite easily introduce a system of
with an equivalent mass. This is an ineffi-
selective mining, crushing and screening
cient means of materials handling com-
directly in the pit. An IPCC/IPCS system
pared to a conveyor.
and limited flexibility • extra-large shovel and truck, which require high-quality road conditions • large shovel and truck, which, in turn, require medium-quality road conditions • medium shovel and truck, which requires lower-quality road conditions • small shovel and truck, which is suitable to soft rock, with good roads
18
• excavator and truck, which is good in
Ins i de Mi n i n g 1 0 | 2 0 1 6
discards the rock and mud stones,
Conveyor belting is a much more effi-
The big consideration is that the weight
Other than the fact that there is one
sending only useable products to the
operator per truck, in my personal expe-
processing plant.
rience, there are never enough trucks
COMMINUTION
Dump truck
Belt conveyor
Gradeability (°)
6-8
18
Payload (%)
50 - 55
90 - 95
No. of operators
1 per truck
none
Power draw (kW/tkm)
0.5 - 1.0
0.1 - 0.15
Cost/tonne($/tkm)
0.35 - 0.50
0.10 - 0.15
Max particle size(inches)
No practical limit
16
GRAPH 1 Total costs and categories
US$/tonne
Table 1 Belt conveying offers lower operation costs and in-pit crushing
DT-system
LT-system
behind the digger to fully utilise it. Time
without considering recapitalisation
means that the backfill areas are much
and time again, the excavator will be
of trucks every five or six years, or re-
closer to the working phases, and dis-
waiting for trucks, meaning lost produc-
placement of trucks being written off
tances of waste material haulage can
tivity at the end of the day.
or destroyed.
be drastically reduced. This means that
The alternative to truck haulage is
A rule of thumb is that, if the trucking
transport distances can be halved.
conveyor belting, which has one-third
cycle times are more than 30 minutes,
There are various options and combi-
of the costs. There might be slightly
then some form of IPCC system needs
nations of IPCC/IPCS systems available
higher capital outlay costs, but the
to be looked at, because the opera-
– it all depends on the requirements
energy costs are lower, and so are the
tion runs at the lower ends of produc-
of the mine. An IPCC/IPCS system can
labour and maintenance costs.
tivity and higher ends of cost.
typically mean up to 90% availability,
The additional capital spent initially
with no stopping or standing times for
years’ time. The life cycleof the crushing
In-pit crushing and conveying concept
conveying systems is so much longer
Conveyor belts can easily work on an
*Dave Thompson is a mining consultant
than the 60 0000 hours of a truck,
incline of between 12° and 15°, which
at DRA Global.
becomes insignificant in a couple of
trucks. It just all makes sense.
In sid e M in in g 1 0 | 2016
19
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COMMINUTION
Fundamentals
of rock breakers
With so many rock breakers and rock breaking systems available on the market, acquiring new equipment can be a challenge in itself. Casper Booyse* sheds more light on these machines.
Casper Booyse, product sales manager, BTi Equipment: Osborn
T
here are typically four options for rock breakers in the mining market and it depends on what the mine’s requirements are as to which op-
tion will be best suited. The first option is a stationary rock
break down to from the maximum sup-
important operational spares. And the
plied oversize.
company also interacts closely with all
There are a few important factors to keep
customers to pre-empt long deliveries on
in mind when acquiring rock breakers or
any long lead items that will be needed
rock breaking systems, and one has to ask
on its products. As an added benefit to
the following questions:
the customer, airfreight of parts is often
• What is the correct system or breaker for
conducted to reduce lead times.
the specific application and duty? • What is the required quality?
*Casper Booyse is the product sales
• What is the technical backup service
manager at BTi Equipment: Osborn.
offered by the company? • How available are the parts and backup service? nicians, trainers, a Parts Division and technical sales staff to support customers
breaker system where the complete unit
with any aspect of aftersales assistance
is fixed next to a static grizzly or crusher,
required. Some of the aftersales services
and assists with the continuous flow and
provided include 24-hour backup services
breaking of oversize material. The second
in the Parts Division, maintenance and
option is breakers, fitted to excavators
operational training, preventative mainte-
for breaking oversize boulders in-pit or, in
nance and machine audits, and routine
some cases, also on a static grizzly.
and emergency service backup.
Third, mobile rock breakers are wheeled,
er systems different is the robust design
ly used for underground applications to
that caters for tough applications where
break rock on ore passes and at the blast-
a lot of raking and clearing of big, over-
ing face. The last option is a semi-mobile
size material is needed. They also match
unit that is a trailer-mounted system.
the systems with a powerpack that can supply more than the required power output to handle the booms and breaker
Rock breaker systems are sized according
fitted to the unit. The company increased
to specific guidelines. These guidelines
the efficiency of the breakers with finer
assist companies, like Osborn, in supplying
tolerances between the internal surfaces
the correct system for the application and
to increase the output of the breakers.
duty. Typically, the guidelines address
This allows a lighter-weight breaker to sup-
the following:
ply the same or more output energy as a
• type of material
heavier competitor breaker, which means
• hardness of material, determined by the
that more powerful breakers can be fitted
specific gravity (SG), bulk density and unconfined compressive strength (UCS) of the ore
A rock breaker mounted on a Hitachi machine
What makes the company’s rock break-
dedicated rock breakers that are typical-
Guidelines
An example of a mobile rock breaker
Osborn has dedicated service tech-
Site needs to determine the choice of rock breaker
to smaller carriers.
Spare parts
• reach required
The company carries adequate stock
• maximum throughput required
at all times, covering all machines sold
• maximum oversize expected
into the market. Daily checks are done
• product required – the required size to
on stock holding to limit any shortfalls on
In sid e M in in g 1 0 | 2016
21
Pipes, Pumps & Valves
The science of pumps and pumping Pumps are among the oldest and most misunderstood machines known to man. Mechanically, they are quite simple, but often very complicated hydraulically. Whether pumping slurry or water, it is rarely the pump’s fault when things go wrong. By Jim Jones*
A
pumping system is about moving liquid from one point to the other and everything in-between. When one plac-
es a pump into a system, it can become very complicated, and often the problem lies in the system within which it operates. Nobody is in the business to make a bad pump. When pumping slurry or water, the liquid to be moved is generally above the pump, but can also be below. Pumps do not suck – a vacuum has to be created, so that atmosphere pushes the liquid up into the pump.
Centrifugal pumps Centrifugal pumps are relatively cheap, mechanically compact and generally the first choice for many applications. These pumps are available as horizontals or verticals, and the pumps vary in hydraulic design using different materials of construction. While there are many different designs used in mining, the most common is the centrifugal slurry pump. Centrifugal pumps represent only 5% of the pumps in industry, but when it comes to cost, these pumps represent 80%
transmission. Slurry pump casings are
• closed with three or more vanes
of the running cost. Note that centrif-
either lined or unlined (single or double
• induced flow (vortex) with
ugals are significantly cheaper than
case) and use a variety of abrasion-
reciprocating pumps.
resistant alloys or elastomers. Water
Centrifugal slurry pumps are much heavier than their water or process
variety of materials, typically cast iron
Closed-impeller pumps
pump counterparts, and are always
for water.
Closed-impeller design allows for the
manufactured using abrasion-resistant
highest efficiency in slurry applica-
materials. A water or process pump
Impeller design
manufactured in the same abrasion-
Centrifugal pump impellers have a va-
It offers good suction performance
resistant materials is not a slurry pump,
riety of designs relating to vane shape,
and is essential for heavy and abra-
and can never be robust enough.
vane angles and flow direction. The
sive slurries. Closed-impeller pumps
three basic designs that are in general
can be sensitive to air locking and
use for slurry applications are:
are particularly sensitive to air.
The casings are generally radially split, thereby gaining access to impeller and
22
and process pumps also use a wide
multiple vanes • semi-open with multiple vanes.
Ins i de Mi n i n g 1 0 | 2 0 1 6
tions and has the lowest rate of wear.
pipes, pumps & valves
Figure 1 Characteristic curve shapes
RISING CURVE
UNSTABLE CURVE
STEEP CURVE
FLAT CURVE
“Lubricants are specifically designed to work in specific types of applications, and mines use very complex and sophisticated equipment that costs lots of money.”
Figure 2 A full set of characteristic curves
HEAD
Jim Jones, director: EMEA Region, Mining Flow Control, Metso
HEAD
SPEED
POWER
CAPACITY
given speed or speeds in terms of head
CAPACITY
(pressure), capacity (flow), efficiency, power and net positive suction head
HEAD
HEAD
required (NPSHR). Without this family of curves, it is impos-
EFFICIENCY
NPSHR
sible to accurately apply any pump to a particular system installation. All the data originates from test work, although
Induced and semi-open impeller
will always be a consequence. Pump
changes in speed and/or impeller diam-
Induced and semi-open impeller pumps
selection is, therefore, often a com-
eter are usually extrapolated. Individual
used in slurry applications are not sen-
promise, to accommodate a variety
curves are:
sitive to air locking and are ideal for
of parameters set by others. Therefore,
• head capacity curve
stringy and fibrous material. They cause
careful thought beforehand is a must
• efficiency curve
less damage to delicate solids, and are
– the more information provided at the
• power curve
good for large solids and viscous slurries.
inquiry stage, the greater the chances of
• NPSHR curve.
However, they offer relatively low effi-
getting the ideal solution.
The shape of the head/capacity (H/Q)
ciency, poor suction performance and
To make even a basic water pump
curve depends on the design of the im-
can suffer some impact damage with
selection, it is essential to be provided
peller, or more accurately the “specific
large solids.
with (as a minimum) the required flow
speed” of the design. The various shapes
rate and the head against which the
and their names are shown in Figure 1.
Impeller size
pump must produce the flow. Even with
Pump performance from a single
The diameter of an impeller governs
a given capacity and head, numerous
speed test is simply plotted on X and Y
head produced at any speed; the width
other data is needed for a trouble-free
axes, as illustrated in Figure 2.
of an impeller governs the flow rate.
installation. This data should relate to
Most, but not all, impellers have addi-
both the liquid handled and the system
Head, not pressure
tional vanes (pump-out vanes) on one or
under which the pump operates.
Centrifugal pumps generate head,
both sides of the impeller.
For slurries, additional data relating to
not pressure.
the solids present is required. Typically,
• 51.0 m head on water is 5.0 bar
vanes are designed to reduce internal
this includes:
• 51.0 m head on slurry of specific
recirculation and provide hydraulic bal-
• density of solid
ance. Compared to water and process
• average particle size
pumps, slurry pumps have impellers that
• maximum particle size and
These additional (expeller or pump-out)
are both larger and wider. Newton’s Third Law states that every
concentration.
gravity (SG) 1.5 is 7.5 bar • 51.0 m on a light oil duty of SG 0.75 is 3.75 bar • m to bar = metres/10.2 x SG • bar to m = bar x 10.2/SG.
action has an equal and opposite reac-
Centrifugal pump curves
tion. In our world, whatever we do when
Pump, or characteristic, curves repre-
measure pressure, even if marked to
designing and or specifying plant, there
sent the capabilities of the pump at a
show metres head.
Something to remember is that gauges
In sid e M in in g 1 0 | 2016
23
Pipes, Pumps & Valves Power absorbed
Table 1 Friction losses across a range of flow rate
Power absorbed by a pump at a given duty point is calculated as:
KW=
M3/HXMXS.G 3.68X Efficiency
m3/h
Friction (m)
Static (m)
Total head (m)
25
2.0
10.0
12.0
50
6.0
10.0
16.0
75
12.0
10.0
22.0
100
20.0
10.0
30.0
125
31.0
10.0
41.0
Friction (head loss) calculations In the absence of a computer, the fol-
curve, select an appropriate method
lowing formula may be used to assess
for estimating friction losses and stick
losses on water and settling slurries at
with it, whether it is tables, charts or
Seven deadly sins
higher velocities, where:
using a computer. Calculate the total
The seven absolutely deadly sins in a
• HF = m loss/100 m
equivalent length of straight pipe, using
pump system are:
• Q = m3/h flow rate
a given pipe size or range.
• off-design operation – the pump may
Next, tabulate friction losses for a
• D = pipe diameter in m
range of flows both below and just
• C = friction factor. 1.85
HF=
Q X C
1
D
4.87
X 3625
• polyurethane lined and plastic = 150 • seamless steel and spun
the pump’s fault • misapplied design
size, or range. Wherever a terminal pres-
• cavitation is vapour, not air in a pump
sure is required (spray bars or cyclones),
• excess nozzle loads
this can be added to the static, or listed
• poor lubrication – make sure that the
in a separate column for inclusion into
Pumps in series Two or more pumps can be operated
pump is correctly lubricated • misalignment means an unfair load on the bearings, which will cause collapse • neglect – it is important to physically
in series to generate more head or min-
attend to pumps to ensure effec-
• spiral welded steel and cast iron = 130
imise wear. While a single-stage water
tive operation.
• rippled bore rubber hose = 110.
pump may generate some 150 m, the
There are numerous charts and tables
resulting rate of wear on slurry necessi-
*Jim Jones is the director: EMEA Region
also available for quick calculations.
tates series pumping.
at Mining Flow Control, Metso
cast iron = 140
Pumps can be operated in parallel
Settling with slurries
where the required flow is not achiev-
Quite simply, if the average velocity in
able with a single pump; two or more
any given line drops below the critical
pumps can be operated in parallel. The
(minimum) velocity, then the coarse
discharge from all pumps is connected
solids start to deposit on the bottom of
to a common delivery line to increase
the pipe. If this situation is allowed to
the flow.
continue, then the pipe will block soon-
As increased friction affects output,
er or later, requiring cleaning, pigging or
the flow does not double when using
a very expensive renewal. Some guide-
the same size pipe. Should the pipe be
lines for pipes to remember are:
too small, only a marginal increase in
• increased velocities result in increased
flow will be achieved – at a consider-
power consumption • increased velocity with slurry brings a greater rate of wear
ably higher cost. In order to achieve a reasonable increase in flow, the pipe diameter should, in general, be increased
• the higher the velocity, the more a slurry behaves like water • the lower the velocity, the greater the risk of any solids settling out • for slurries, vertical pipes are better than inclined • never overestimate losses; always use best estimate • for slurries, obtain maximum data at the inquiry stage. The more information available, the better the pipe selection and estimate of friction. The golden rule is: if in doubt, seek professional help. To calculate a system
24
vibrate or fall to pieces, but it is not
above the required flow in a given pipe
the total head figure. Typical values for c include:
to keep friction losses down.
Ins i de Mi n i n g 1 0 | 2 0 1 6
Operating multiple pumps in series improves efficiencies
Mine water & wastewater management
Nitrate contamination in mine water One of the challenges that mines have to deal with is nitrate contamination in mine water. With water being scarce and mines environmentally regulated, nitrate contamination leaking through underground mine workings can be a threat.
U
underground mine workings during a
New technology
blasting campaign, according to recent
BME has evolved cold emulsion explo-
international studies, says Neil Alberts,
sives technology to new levels over the
operations manager, BME.
past three decades to help keep nitrates
P TO 28% of nitrates from tradi-
the overall quality of recycled water
tional ammonium nitrate fuel oil
and increase its applications on and off
(ANFO) explosives can leach
the mine site.”
into water draining through
High levels of ANFO wastage suggest
out of mine water. This technology assists
that it may be a contributor to nitrate
mines in preventing possible groundwater
levels in water passing through mine
contamination and allows for the optimal
workings, although the mining sector typ-
recycling of water on-site.
ically accepts that about 30% of ANFO
Neil Alberts, operations manager, BME
“Among the characteristics of our emul-
No oil Another advantage of emulsions
delivered to a blast site is not consumed
sions range is excellent water resistance,
highlighted by the tests was that no
in blasting. As mines work to prevent or
which means that the explosive material
oil was released, ensuring that water
mitigate environmental damage, pollu-
does not dissolve readily in water,” he
contamination by oil is also prevented;
tion or ecological degradation, the levels
says. “This reduces the amount of nitrate
both the nitrate and the fuel phases
of nitrate in water are usually monitored
leaching to negligible levels.”
of the mixture are bonded tightly by
– as high nitrate levels can render water unsafe for drinking. But, there is some
Tests conducted by the company indicated that, after being immersed in wa-
the emulsifier. “BME has already contributed to
good news. “These levels can be re-
ter for a month, its emulsion released only
environmental sustainability on mines
duced to as little as 2% by applying best
about 0.7% of its nitrate content.
by incorporating and consuming pre-
practice, but the long-term solution lies in
Alberts says that the key factor here is
explosives that do not release nitrates into
the effectiveness with which the oil in the
helping mines to dispose of these
water sources,” says Alberts.
emulsion surrounds and isolates the small
liquids safely and cost-effectively,” he
“By removing the possibility of nitrate
viously used oil in its emulsion products,
droplets of saturated oxi-
leaching from blasting chemicals un-
diser salt, preventing them
derground, mines can reduce the risk of
from dissolving in water.
groundwater contamination as water
“On the other hand, our
drains out of working areas,” says Alberts.
tests confirmed that ANFO
“At the same time, where mines are mak-
dissolves completely
ing efforts to recycle water from under-
when it comes into con-
ground, lower nitrate levels will enhance
tact with water.”
says. “The way we
“By removing the possibility of nitrate leaching from blasting chemicals underground, mines can reduce the risk of groundwater contamination.”
have evolved the matrix also ensures that no oil is released when our emulsion comes into contact with water at the stope face.”
In sid e M in in g 1 0 | 2016
25
Mine water & wastewater management
Using tailings for brickmaking The Witwatersrand Basin, in the economic heart of South Africa, has two main problems. One is the significant amount of mine tailings from gold mines in the area. The other is the need for building materials.
I
N A TECHNICAL paper titled ‘The
environmental legislations, has caused
viability of using the Witwatersrand
the scientific community to focus on
gold mine tailings for brickmaking’,
finding innovative methods of utilising
the authors, M Malatse and S Nd-
mine tailings. Even though some appli-
lovu, examine the possibility of using gold mine tailings in the production of bricks. By doing this, mines will be able to save costs on tailings, as disposal costs are very high, and save the environment and ecological systems. At the same time, it will lessen the pres-
There is a significant need to develop other longterm, commercially viable uses for mine tailings in order to minimise the disposal costs and the impact on the environment
particle size, and quantitative chemical
erated tailings have
analysis. The particle size analysis was
been exploited, such
done by physically screening the sam-
as in the building
ples using test sieves of various screen
of slimes dams and
sizes up to 212 µm.
backfill in under-
The authors add that the phase min-
ground mines, these
eralogy analysis was carried out using
uses do not take up
an X-ray diffractometer operated with
more than a fraction
Co-K radiation generated at 40 kV and
of the total amount
50 mA. The chemical analysis was car-
of tailings in the
ried out using wavelength dispersive
Witwatersrand region.
X-Ray fluorescence (SRF) spectrometry
There is, therefore,
operated with a rhodium tube excita-
a significant need to term, commercially
natural construction
tion source.
Brickmaking process
viable uses for mine tailings in order
The authors write that different mixing
to minimise the disposal costs and the
ratios of tailings, cement, and water
authors write that gold mining and pro-
impact on the environment,” write
were used in the brickmaking process.
cessing wastes contain large amounts
the authors.
From each mixture, a number of bricks
material of traditional building materials. In the introduction of the paper, the
of sulfide minerals such as pyrite, which generate acid mine drainage (AMD).
Materials and methods
were cast and dried. “The three feed material (tailings,
The materials used in the test work were
cement, and water) were mixed in the
challenges resulting from AMD and the
gold mine tailings, tap water and ce-
appropriate ratios in a commercial
government and mining companies are
ment as a binding material. Represent-
mixing machine. Dry mixing was done
under pressure to find viable solutions
ative samples used in all experiments
first and then a controlled amount of
to this problem. “This, coupled with the
were prepared using a riffle splitter.
water was added while continuing to
South Africa is currently faced with the
increasing landfill costs, and stricter implementation and enforcement of
26
cations of the gen-
develop other long-
sure on quarrying for
A recent study looked at the possibility of using tailings dams for brickmaking materials
Ins i de Mi n i n g 1 0 | 2 0 1 6
The gold tailings were characterised
mix thoroughly. The total mixing time
by investigating the phase mineralogy,
was 15 minutes. The mixture was then
Mine water & wastewater management table 1 Different mixtures used in brickmaking
Mixture number
Tailings (kg)
Cement (kg)
Water (ℓ)
1
2
1
0.6
2
14
2
2.65
3
9
6
3.0
4
7
8
2.5
5
10
5
2.5
6
12
3
2.5
7
5
10
3.3
8
10
5
3
table 2 Average compressive strength of bricks cured differently
Mixture
Average compressive strength (kN/m2) Water
Oven
Ambient
water absorption tests showed that
1
141
165
157
water absorption is higher in neutral
2
20
25
29
solutions compared to acidic solutions.
3
325
359
318
4
440
439
323
5
262
261
234
ble at 0.06%,” write the authors. The
6
215
235
230
authors recommend that more tests
7
530
479
454
should be done on a wider range of
8
149
98
127
The rate of absorption is high in the first day, but then stabilises. The weight loss over a seven-day period was negligi-
tailings to cement ratios to manufacture a stronger brick. “In addition, the size of the tailings
cast into the brick moulds. The brick
human exposure to tailings, conse-
used as aggregate should be varied to
moulds were then placed on a vibrat-
quently reducing the effect that mine
a wider range. This can be achieved
ing machine for five minutes in order to
waste has on the health of inhabitants
by adding overburden to the fine
fill the voids in mixture comprehensively
in the mining area. The use
and, thus, prevent the formation of
of gold mine tailings
The test revealed that more
air pockets.
for brickmaking also
cement was used in the
“The brick were then labelled and al-
constitutes an ad-
tailings material.”
manufacture of the tailings bricks than in commercial
lowed to cure for 24 hours. Three curing
ditional source
methods were used – sun dried, oven
of revenue for
bricks, which can be a
dried at 360°C, and cured in water for
the gold mining
disadvantage, as ce-
24 hours. After curing, the bricks were
companies and,
ment is more expensive.
de-moulded using an air compressor,
in the process,
weighted, and tested for compressive
creates jobs,”
strength,” write the authors.
write the authors.
“Looking at the bigger picture, the use of tailings as brickmaking material would have great advan-
Strength testing
Conclusion
The bricks were tested and, in the
In the paper’s conclusion, the
conservation and reduction of waste
process, force was applied on the
authors write that the results from X-ray
management costs.
brick until the brick failed. The force
powder diffraction (XRD) and XRF
measured at failure was documented.
showed that the chemical composition
uranium is present in Witwatersrand
The mixture ratio that gave the highest
of the Witwatersrand gold mine tailings
gold tailings, extensive research with
compressive strength was then em-
is similar to that of the clay materials
regard to the chemical properties and
ployed for further tests.
used for commercial brickmaking.
the chemical stability of the bricks
“It was then concluded that it would
Cost implications
be technically viable to use the tailings
“Since the use of tailings for brick-
for brickmaking. Following the South
making conserves natural resources,
African masonry standards for brick-
one could say that the benefit to
making and testing, it was found that
the environment outweighs mere
the commercial brick has an average
economic considerations.
compressive strength of 750 kN and
tages in terms of environmental
“Since the XRD analysis showed that
produced from gold mill tailings is required,” conclude the authors.
follow the link
that the strongest bricks made from
For the complete technical paper published in the SAIMM Journal, go to:
companies have to spend less on
the tailings have an average compres-
waste management, while reducing
sive strength of 530 kN. “Results from
http://bit.ly/2bG9bRA
“The use of tailings would mean that
In sid e M in in g 1 0 | 2016
27
Mine water & wastewater management
Variety of
analytical solutions
The current drought situation around the world emphasises the need to take care of all water resources. Combine that with environmental legislation and having to save costs wherever possible, and the need for a practical solution in organics monitoring arises.
O
NE SUCH PRACTICAL solution
of organic carbon (TOC),” says Galliford.
is the range of monitoring
When it comes to compliance reporting,
tools from SMM Instruments
the tools typically used are oxygen de-
for analytical and laboratory
mand parameters (based on historical
applications. As an international agent,
practice); however, the time required for
the company supplies sub-Saharan
BOD testing (days) or COD (hours) makes
web browser interface allows users to
Africa with, among others, GE Power
it impractical for the real-time deci-
remotely monitor and control operations
Water & Process Technologies’ analytical
sion-making required for process control.
and results using a web-based interface via the instrument’s Ethernet port.
instruments. The instruments are aimed
“TOC analysers installed for discharge
to assist companies to prevent product
monitoring tend to include a correlation
loss, lower waste treatment costs, and
to the oxygen demand test and report
Accessories
reduce system maintenance and energy
in mg/ℓ BOD or COD. When used for
“To enhance the analysers, there are a
consumption through organics monitoring
process control, output is typically in
range of accessories to choose from.
in wastewater treatment.
C. TOC enables online, near real-time
These include an air purifier that removes
reporting of organic contamination,”
CO2 from the air and a filter panel that
Monica Galliford, national sales manager, SMM Instruments, explains that process and wastewater
explains Galliford.
filters one sample stream and is auto-
matically cleaned by back-flushing with
contamination includes organic and
Models
inorganic components. “Sources of
The range of GE instruments
organic contamination include process
developed for process water and
rate of each sample stream stops or
chemicals, heat transfer fluids, and food
wastewater include:
when consumables need replenishing.
products, as well as naturally occurring
• M9 Laboratory and Autosampler
Other accessories include a mounting
organics in surface- and groundwater.”
• M9 On-Line
stand, a sample peristaltic pump and
• M9 Portable
multistream configurations.
To analyse the water, laboratory personnel make use of a variety of
• M5310 C On-Line
monitoring tools to prevent corrosion
• InnovOx Laboratory and On-Line.
and equipment damage, and optimise
The Sievers InnovOx Laboratory and
treatment processes.
On-Line TOC analysers offer a variety of
“The tools used for organics monitoring
28
“Sources of organic contamination include process chemicals, heat transfer fluids and food products, as well as naturally occurring organics in surface- and groundwater.”
Fail-safe sensors detect when the flow
features and benefits, and measure up
include oxygen demand testing, an in-
to 50 000 ppm of TOC. The instruments
direct measurement of organic carbon
are easy to operate and offer preset
(BOD or COD), and direct measurement
protocols for easy start-up. The Ethernet
Ins i de Mi n i n g 1 0 | 2 0 1 6
compressed air,” says Galliford.
www.smmafrica.com
Electrical Instrumentation & Control
Upgrading trolley
assist technology
Although trolley technology was first introduced in 1981 in South African mines, it is still used by various mines to assist trucks uphill. The latest upgrade in trolley assist technology sees the launch of fully automated 11 MW DC containerised substations.
T
ROLLEY ASSIST solutions are
in the mining industry.
The company offers full
normally installed on an uphill
An interesting fact of
assembly, installation,
stretch where mineral-ore-carrying
this new order is that
testing and commis-
haulage trucks struggle with the
90% of components in
sioning of these fully
gradient of the incline due to the diesel
the containerised sub-
automated facilities.
engine’s horsepower limitations.
stations are entirely
The trolley assist solutions supply electric
The container includes
manufactured by Siemens, compared to
the 1.8 kV DC switchgear, rectifiers, 33
power to the wheel motors of the haul-
past units that contained approximately
kV ring main unit, Siprotec AC protec-
age trucks, which enables the vehicles to
30% Siemens components.
tion device and Sitras Pro DC Feeder
move faster uphill. This results in quicker turnaround times and higher productivity.
“Consistent innovation has kept us at the forefront of mining technology, and
protection device. The control and protection of the entire
sourcing nearly all of our components
substation is automated with a Siemens
provide electric power to the overhead
internally means greater quality control,
PLC and distributed I/O units connected
DC power lines, which, in turn, provide
improved functionality, and greater
via Profibus, significantly reducing the
DC power to the adapted diesel-elec-
capacity,” says Phiwa Thindaw, project
number of interface cables between
tric haulage trucks. One of the three
manager, Siemens SA.
equipment and allowing for the ef-
The new 11 MW Siemens substations
launched units will be used to power a
Siemens’ DC containerised substations
fleet of Komatsu 960E trucks, which are
are manufactured in Pretoria, with com-
substation and equipment via a touch
among the industry’s biggest and highest
ponents currently imported from Germa-
panel. Cooling of this unit is provided by
capacity mine haulage vehicles, with a
ny. “The company aims to manufacture
two inverter air conditioners, keeping the
load capacity of 214 m3 or 327 tonnes.
components such as switchgears and
inside temperatures between 18°C to
control panels locally in future,” says Joey
22°C under normal load conditions.
Each 11 MW containerised substation boasts 1.8 kV of DC voltage and up to
Govindasamy, lead: Rail Electrification
10 000 amps to ensure that it can run
Business Unit, Siemens SA.
two trucks continuously, three trucks for
fective control and monitoring of the
“Our experience gained over the past 20 years of providing DC mobile substations for trolley assist projects at various
10 minutes, or four trucks for one minute
Specifications
along the overhead power lines. This
Each substation is housed in a 6 m x 3.3 m
cess of this project,” concludes Karl van
combination of substation and overhead
x 3 m container that weighs approximate-
Rensburg, Siemens’ lead engineer who
line is known as trolley assist technology
ly 8.5 tonnes when fully commissioned.
designed the substation.
mines has greatly contributed to the suc-
At the launch of the latest fully automated DC containerised substation are Siemens SA’s Sabine Dall’Omo, CEO, and Clifford Klaas, executive director: Corporate Affairs, HR and Sustainability
In sid e M in in g 1 0 | 2016
29
Electrical instrumentation & control
Importance of maintaining transformers Just because there are limited moving parts in transformers, it doesn’t mean they are maintenance-free. Labelled as among the most efficient pieces of equipment developed by man, transformers require preventative maintenance for optimum performance.
T
WO OF THE main benefits
“We are able to provide verifiable
the transformer to replacing gaskets
achieved from transformers, when
reporting on the condition of the
and cone rubbers right up to major on-
a comprehensive preventative
transformer using oil sampling, analysis
site repairs including replacing offload
maintenance and service strategy
and thermal graphics surveys, all of which
tap changers.
is in place, are optimum performance
meet international quality standards
and a long functional life.
reporting requirements and are accepted
offer this level of support to industry and
by most insurance,” says Mans.
ongoing training ensures that our team
“Preventative maintenance of transformers is critical, not only from an
“We are one of few OEMs that can
is kept abreast of technology as well
operational reliability perspective, but also
On-site
because a well-structured maintenance
As part of on-site preventative
height, firefighting and HV regulations,”
programme will significantly extend the
maintenance, skilled individuals will
says Mans. Other maintenance activities
life of the transformer. In most cases, it is
conduct transformer oil sampling to
done on-site deal primarily with the
not inconceivable for a well-maintained
ensure accuracy and reliability. The way
condition of the transformer and could
transformer installation to have a lifetime
in which the sample is taken is crucial to
entail purification and regeneration as
that outstrips that of an average human,”
the result; therefore, sampling tins are only
well as vacuum treatment being done to
says Andre Mans, COO, WEG Transformers
used once to avoid cross contamination.
eliminate entrapped air.
Africa (WTA), a division of Zest WEG Manufacturing. “This could between
In addition to the visual assessment and oil sampling and analysis, the WTA team undertakes thermal
40 to 50 years.” To assist customers with maintaining transformers in ideal conditions, WTA offers a suite
as operational skills such as working at
“Preventative maintenance of transformers is critical.”
of support services
graphic surveys to determine areas where excessive heat may be present in the transformer and other electrical equipment. Samples are brought back
for its transformers customer base.
to the oil-sampling laboratory at WTA's
These services include preventative
facility in Heidelberg to analyse the oil.
maintenance programmes that can be
The oil sample is compared to a base
structured to accommodate customer
line, which enables the technicians
needs and/or budgets. According to
in the laboratory to identify potential
Mans, it is most important for customers to
problems that cause transformer failure.
do an initial assessment of the transformer
Other tests include kV or dielectric
installation as this will allow a base line to
strength testing to determine the
be verified and, following any corrective
insulating properties and DGA (dissolved
action, a customised support programme
gas analysis), which provides a clear
can be implemented to ensure the
indication of internal failure conditions.
optimum reliability of the transformer.
Acid levels are also checked against
A team of skilled technicians will rate the transformer according to the application
Andre Mans, COO, WEG Transformers Africa
acceptable standards.
in which it is being used during a
Follow-up interventions
preventative maintenance assessment.
Following the comprehensive oil analysis,
Then, the team will implement a needs-
WTA’s mobile field service teams are able
based maintenance strategy with the
to implement interventions to address
objective of reducing the probability of
identified issues. These interventions could
transformer failure.
include anything as basic as re-torqueing
In sid e M in in g 1 0 | 2016
31
Minerals processing
Processing fine
and ultra-fine coal Fine and ultra-fine coal beneficiation is not a new science in the coal industry but an important part of coal processing. Johan de Korte* takes a look at processing options available in the market and how they have been performing in the mining industry.
T
HERE SEEMS to be much confu-
which is -6 mm, was just screened out of
raw fines were dewatered using dewa-
sion between the terms fine coal
the plant feed and discarded. Roddeck
tering screens and added to the PSS
and ultra-fine coal. To shed more
screens were used to remove the duff
raw. This made a positive contribution. In
light on the difference: normally,
from the plant feed. In later years, when
the mid-1980s, spirals were introduced in
coal processing plants start with a feed
most of the plants in KwaZulu-Natal pro-
the coal industry and proved very bene-
that is crushed to 50 mm top-size and
duced coking coal, flotation became a
ficial for that specific market, increasing
then de-slimed at 1 mm size by using
standard part of the process. The coal
the PSS yield by between 1% and 1.5%.
vibrating screens. The -1 mm material
was amenable to flotation and typically
goes to hydro-cyclones for classification
resulted in product yields of about 80%,
Coal processing today
and the underflow from the cyclones is
with 10% to 12% of ash product, so flota-
Currently, the main fine coal processing
the size fraction between 1 mm and 150
tion worked very well there.
equipment is spirals, which are still the
μm. The Australians call it sand-sized – in
During the 1970s and early-1980s, there was an agreement with Japanese steel
industry. A few teetered bed separators
The overflow from the cyclones, which is
mills to supply them with a 7% ash coal
(TBS), and reflux classifiers (RC) are com-
the really fine material of -150 μm, is the
and the coal mines in the Witbank area
ing into the local market, and two of the
ultra-fines.
did a double-stage wash of the coal
mines also use dense-medium cyclones
to produce the low-ash coal, as well as
to process the fine coal. Froth flotation
there was no such thing as fine coal
power station smalls (PSS) with a speci-
is the only process that really works on
beneficiation, or very little of it. Duff coal,
fication of 27 MJ/kg. In those days, the
ultra-fine coal.
In the early years of the coal industry,
Wescoal’s coal processing plant
32
fine coal processing workhorses in the
South Africa, it is referred to as fine coal.
Ins i de Mi n i n g 1 0 | 2 0 1 6
Minerals processing Spirals
~0.120 are typical for a TBS. One of the
problem and typically runs at about
Spirals are well proven in South Africa
big advantages is that it can cut at low
~1.4 kg/feed tonne. The main reason
– they have been in use for 30 years
density – ~1.50 is quite feasible.
for that is the efficiency of the new
at least. The typical Ecart Probable Moyen (EPM) value for spirals is >0.150, and the cut density is normally higher than 1.70. Spirals are simple-to-operate, low-cost units and are really good at removing pyrite from fine coal. One of the drawbacks is that spirals
Spirals are currently the main fine coal processing equipment and serve as the industry's workhorses
have a low capacity
Reflux classifier
generation of magnetic separators. A typical fine coal dense-medium
A relatively new tech-
circuit looks exactly like a conventional
nology in South Africa is
dense-medium circuit, with the only
the reflux classifier. There
difference being that it has magnetic
are full-scale installations
separators instead of drain and
at two mines in Mozam-
rinse screens.
bique and at one mine in Limpopo. Typically, a
Froth flotation
RC 2020 unit which has
Froth flotation is the only viable
a capacity of ~100 t/h is
process for ultra-fines. There is limited
used. It is very similar to
application in South Africa at present,
a TBS – the principle of
with only two or three plants using
per unit, so a plant usually requires a
operation is, for all practical purposes,
froth flotation, while it is becoming
large number of them.
the same. The control is the same, the
a standard feature for the plants
EPM is the same, and it can also cut at
in Mozambique.
Another problem with spirals is that because they are so easy to operate, they don’t ask for attention and, as a result,
low densities.
Once serious coal mining starts in the Limpopo, especially in the Musina area,
they don’t get any attention. Therefore,
Dense-medium cyclones
we unfortunately see much neglect
Dense medium is not a new process.
be a very important part of processing
of spirals in the industry. Spiral circuits
The first dense-medium plant to process
Limpopo coal.
are normally simple in design. Hydrocy-
fine coal was built in Belgium in 1957.
clones also feature quite prominently
Since then, several plants have been
but also an expensive process.
in a spiral circuit and are used to both
built around the world, including
Something that is important to
thicken and de-slime at the same time.
Europe, the USA, Australia, and South
remember is that flotation will not work
Africa. There are currently two fine coal
on weathered or oxidised coal.
Teetered bed separator (TBS) TBS units are in use at a few plants in South Africa. The advantage with the
dense-medium plants in South Africa both are in successful operation. Dense medium is the more efficient
froth flotation will be required, as it will
Froth flotation is an effective process,
Dewatering and drying When it comes to fine coal, benefici-
TBS is that it has a high capacity: 100
process compared to the previous
ation is only half of the problem when
t/h for a 3.65 m diameter unit. It is also
mentioned processes. Typically, the EPM
producing thermal coal. One has to
simple to operate: basically controlling
value is around ~0.08. One thing that
also dewater the product in order
of bed density and fluidising water.
everyone was worried about with dense
to reach the target calorific value
TBSs are really effective at removing
medium is the magnetite consumption,
(CV). Keep in mind that, when using
high-density fines. EPM values of about
but this has since proven not to be a
dewatering screens, the product is
Dense-medium cyclones in the fine coal processing plant
figure 1 Spiral circuits
In sid e M in in g 1 0 | 2016
33
table 1 TBS processing results by size fraction
Aury Africa provides customized solutions for the coal industry. We manufacture a comprehensive range of fine and coarse coal centrifuges. Aury products are manufactured from high quality raw materials to exacting standards, ensuring efficient, reliable and cost effective products to all of our customers.
Size
Feed
Product
Discard
Yield by ash balance
Feed ash/ Product ash
+1.0 mm
27.6
9.1
46.4
50.4
3.03
1.0 mm x 0.5 mm
31.8
13.4
58.7
59.4
2.37
0.5 mm x 212 μm
29.9
21.0
86.7
86.5
1.42
212 μm x 100 μm
38.8
35.7
90.5
94.3
1.09
-100 μm
52.8
51.5
77.3
95.0
1.03
Mass % Cumulative
Ash % Fractional
Ash% Cumulative
table 2 Influence of slimes on spiral product ash
Screen size(μm)
Contact us for more information on our centrifuges and centrifuge components.
Mass % Fractional
+1 000
0.5
0.5
10.4
10.4
-1 000 + 500
19.1
19.5
10.5
10.5
-500 + 250
26.7
46.2
11.3
11.0
-250 + 150
10.4
56.6
11.9
11.1
-150 + 106
14.0
70.6
15.3
12.0
-106 + 90
5.1
75.7
21.9
12.6
-90 + 75
4.8
80.6
25.1
13.4
-75 + 45
4.8
85.4
38.3
14.8
-45 + 25
5.1
90.5
40.2
16.2
-25 + 0
9.5
100.0
44.2
18.9
Reflux classifiers in coal processing plant
Conclusions The fine coal process chosen
dewatered but still has up to 25% surface moisture. Centrifuges are more expensive, but one can get down to about 14% to 16% surface moisture. Thermal drying can get down to 0% surface moisture, but thermal drying
Aury Africa - Pushing the limits, setting the standards 19 Graniet Road, Jet Park, Boksburg 011 026 6642 info@auryafrica.co.za
is more complicated. However, if one does the economics, it does prove to
depends on the specific requirement. The cheap option is not always the most economic one. De-sliming of the feed and product needs to be done well to produce good-quality product, and dewatering is as important as beneficiation of coal.
be viable, although it is not used in
*Johan de Korte is a senior
South Africa at the moment.
researcher at the CSIR.
34
I n s id e M in in g 1 0 | 2 0 1 6
Minerals processing
Down memory lane Taking a trip into the history of coal processing will soon be a reality when the Geology Museum, based in Museum Africa, Johannesburg, completes its display on coal. Initiated by the Southern African Coal Processing Society (SACPS), the exhibit will offer a variety of educational information. T THE MOMENT, the Geology
A
The initiative started last year and Kath-
later, the first double-stage Chance plant
Museum presents various ge-
erine James, curator: Geology Museum,
came into production. This plant was ca-
ological items, with opportuni-
City of Johannesburg, is still in the process
pable of processing some 100 000 tonnes
ties to touch a variety of rocks.
of getting everything together, hoping to
of raw coal per month. Dense-medium
But there has never been a coal display,
finalise the display at the end of the year.
processing using magnetite as the me-
and Mark Cresswell, committee member,
“The exhibit is estimated to cost about
dium came into use after about 1951,”
SACPS, noticed this absence.
R40 000 and will display 95 specimens of
“I have always been in awe of the fact
coal, the geology of coal, images and
writes De Korte. He goes into more detail about the
that Johannesburg is in within 100 km of
literature depicting the history of coal in
accepted standard for high-grade coal
many major coal, diamond, platinum
South Africa as well as coal processing
produced prior to 1922 and how coal
and gold mines, which is quite unique in
throughout the decades, to name a
preparation has progressed since then.
the world. The museum showcases many
few,” says James.
De Korte also details coal institutes and
facets of our country’s economy and
how they came about.
history. So I spoke to my colleagues on
History
the committee and said it would be nice
Cresswell points out an interesting fact
Memorabilia
to have a display of coal, especially since
about how mines are now looking at the
“We have a lack of mining equipment
there is already a display of the minerals,”
old mines of the 1930s to do pillar extrac-
to assist us in depicting the history of
says Cresswell.
tion. These old mines were relatively shal-
coal and coal mining in South Africa.
He adds that the SACPS wants to further
low underground mines and have now
Any memorabilia will do to add to the
the interests of coal processing and edu-
opened up as surface mines. “People are
coal collection, as long as it doesn’t fall
cation in the country, so the organisation
now finding items that were left in the old
apart,” says James. She adds that do-
readily agreed to sponsor a display unit
mines, from funny old mining hats to horse
nors’ names will be attached to the items
with items and information depicting
shoes, showing that they used pit ponies,”
and whatever is not displayed will go into
coal, mining, and coal processing.
says Cresswell.
storage where researchers can research
According to the technical paper
Katherine James, curator, Geology Museum, and Mark Cresswell of the SACPS
the items.
‘Coal preparation research in South Africa’ by GJ de Korte*, the first colliery
*The technical paper was first published
opened in 1864 near the town of Molteno
in The Journal of The Southern African
in the Eastern Cape. De Korte writes
Institute of Mining and Metallurgy.
that the earliest record of coal washing goes back to 1905, when the first of five jig plants was installed in the then Natal province. “In 1934, a 90 000 tonne per month Rheolaveur plant was commissioned in the then Transvaal province and, a year
follow the link To read more about coal preparation research in South Africa, go to: www.scielo.org.za/pdf/jsaimm/ v110n7/05.pdf
In sid e M in in g 1 0 | 2016
35
EDUCATION & training
Ensuring the quality of raw materials In the manufacture of polyethylene pipes, controlling the quality of the raw material used is as important as controlling the quality of the final installation. A fundamental part of ensuring dependable, high-quality pipe production is rigorous testing. By Ian Venter*
T
• Commissioning and testing of the prod-
economic consequences.
The designer needs to validate that all
When it comes to designing a pipe
the aspects related to these assumptions
system, certain design assumptions
are valid and true. For that reason, test-
are made:
ing the various aspects or properties of
• The product installed in the system will
the product at different stages is critical.
ESTING IS ESPECIALLY important when it comes to mining applications, where the stakes are high. Failure to detect faulty
pipes can have severe safety and
be compliant to a set of standards. • Storage and handling will be
uct/system will follow a set standard. • Usage of the system will be accordance with the set standard.
End users, specifiers and designers need
Ian Venter, product specialist, Marley Pipe Systems
standard (usually a SANS standard),
to understand the roles and responsibil-
which generally covers aspects such as
carried out in line with the
ities of various role players influencing
raw material, the pipe and its geometry,
component’s capabilities.
the life expectancy of their system. The
fittings, and the overall system. If these
product is manufactured to a specific
requirements are met, a certain life
• Installation and jointing will be
36
executed according to a set standard.
Ins i de Mi n i n g 1 0 | 2 0 1 6
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EDUCATION & training Failure to detect faulty pipes can have severe safety and economic consequences expectancy can be assumed. The SABS and other testing bodies are responsible for the initial standard testing in its entirety. With this, they also issue a set of permit conditions, which stipulate factors such as the standard, testing samples, secondary sampling, audit frequency and further onsite responsibilities of the manufacturer. Only if all permit conditions are met, may the manufacturer continue marking their product in compliance with the standard. This is important to understand because,
End users, specifiers and designers need to understand the roles and responsibilities of various role players influencing the life expectancy of their system
in the past, when somebody saw a prod-
Test results After determining the vitals, it’s crucial to determine vital components of the system and allocate specific property tests. It will also be important to draw up a QC plan, which shows the various dates, tests, test procedures, responsibilities and pass/fail criteria. From the test results, it’s possible to deduce whether the product complies with a standard and the required properties of that standard and, therefore, make a conclusion that the product will perform as expected and designed for.
Considerations There is a natural progression in all product development. The raw material, being an important component, determines the majority of properties that the
uct with an SABS mark on it, they were assured that the product
resulting product exhibits. It is, therefore, no surprise that the most
was compliant. With this new understanding
development goes into optimising the properties of raw materials.
of permit conditions, however, we now see that the responsibili-
One such example is the progression of PE63 to PE80 to PE100.
ty is placed squarely on the manufacturer – and not the testing
This is a natural progression and allows for better product prop-
body – to perform all tests necessary to prove compliance.
erties, like increased bore capacity, better resistance to environ-
Most important component The QC (quality control) testing of raw materials is probably the
mental stress cracking and better thermal stability. This natural progression has taken place entirely without compromising on the product’s overall performance.
most crucial test that needs to take place, as it accounts for 80% of the product cost. Why is this important? Manufacturers
*Ian Venter is a product specialist at Marley Pipe Systems.
often look to raw materials as the best opportunity for cutting costs, which sometimes results in inferior-quality materials making their way into pipe production. The addition of inferior regrind materials can cause weak points, which may lead to major failure of the entire system, jeopardising the safety and health of the community.
Good testing frequency A good testing frequency would be per product type, product size, product class (pressure or stiffness), raw material batch, machine and per manufacturer – all in line with the specific standard and with the specific permit conditions mentioned previously. Raw material testing should occur: • prior to production • after production • prior to delivery • after delivery (prior to installation).
Vital signs All products have specific failure modes linked to material and product properties. From these, we need to determine the failure modes critical to an application. In human terms, these would be things like temperature, heart rate, blood pressure, etc. For polyethylene, we look at three vital failure modes: • Material stress: the risk of joints failing or pipes cracking as a result of internal hoop pressure or ground axial or bending stress from expansion or contraction, or ground movement. • Environmental stress cracking: external or internal cracks in a plastic caused by localised stresses through contact with the pipe wall internally and/or externally. • Thermo-oxidative failure: degradation and embrittlement of the plastic due to thermo-oxidation over time, as a result of temperature and/or UV exposure.
In sid e M in in g 1 0 | 2016
37
Hear from the most influential executives active in investing and developing mining projects on the African continent: Featured Speakers ROGER BAXTER Chief Executive Officer Chamber of Mines of SA
NICK HOLLAND Chief Executive Officer Gold Fields Limited
MASHALE PHUMAPHI Managing Director Shumba Energy
MARK BRISTOW Chief Executive Officer Randgold Resources
CLIVE JOHNSON President and Chief Executive Officer B2Gold
ALWYN PRETORIUS Regional Senior Vice President Newmont Mining
TOM BUTLER Chief Executive Officer ICMM
GRAHAM KERR Chief Executive Officer and Managing Director South32
RICK RULE President and CEO Sprott U.S. Holdings Inc.
MARK CUTIFANI Chief Executive Officer Anglo American
SHEILA KHAMA Director African Natural Resources Center (AfDB)
ANTÃ&#x201C;NIO CARLOS SUMBULA Chairman and Chief Executive Officer Endiama
ALAN DAVIES Chief Executive Officer Energy & Minerals Rio Tinto
BEN MAGARA Chief Executive Officer Lonmin
MIKE TEKE President Chamber of Mines of SA
ROBERT FRIEDLAND Executive Chairman and founder Ivanhoe Mines
DR. DAMBISA MOYO Macroeconomist
JOHN WELBORN Managing Director and Chief Executive Officer Resolute Mining
BRAD GORDON Chief Executive Officer Acacia
ANDREW PARDEY Chief Executive Officer Centamin
NIKOLAI ZELENSKI Chief Executive Officer NordGold
6-9 FEB 2017 CAPE TOWN | SOUTH AFRICA
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MARKET news
from around the continent Bearing all for gears Reducing power loss and oil consumption of gear units by 30% is what Voith has achieved with the new BHS AeroMaXX technology for turbo parallel-shaft gear units. The company has also been able to increase the gear unit efficiency by up to 0.5%. Reducing the power loss and oil consumption of gear units means far better operating behaviour and reliability of engine and gear units. Due to high-pitch line velocities of up to 200 m/s, oil swirling and oil squeezing in the gear mesh accounts for a substantial part of the power loss of high-speed turbo gear units. An inner housing in the direct vicinity of the gear set absorbs heat and dissipates it into the bottom area on the external surface of the inner housing via cooling oil. This means that a substantially smaller volume of oil is required for the actual lubrication of the teeth contact surfaces, while the swirling oil/air mixture
Kansanshi has opted to renew its fleet of blast hole drill rigs with Sandvik drill rigs
itself is minimised. In addition to the inner housing, the technology also includes new BHS EcoMax sleeve bearings on the pinion shaft. These hydrodynamic bearings are optimised specifically for the application, and guarantee high energy efficiency along with significant oil savings. The technology reduces losses by separating lubrication and cooling, with a solution that has passive mechanical characteristics and does not require any additional accessories or components such as pumps or seals.
The new BHS AeroMaXX technology for turbo parallel-shaft gear units
Opening new doors Due to its ability to meet the pricing and delivery requirements of a customer, DCD Ringrollers is expanding into new market segments with its recent forging of a large nozzle component weighing over three tonnes. The company is also expected to now be able to participate more assertively in the local markets for these and similar components. “With a height of 850 mm, this forging is the largest of 43 components ordered by a South African customer for a pressure vessel application,” says Dion Booyens, executive director, DCD Ringrollers. “With this exciting achievement under our belt, we now look forward to the prospect of forging other components – such as even larger and heavier nozzles, bushes, rolls and pinions,” he says. “In particular, we are in a
position to manufacture a larger range for markets where pressure vessels are in use and heavy section nozzles are required.” The company’s manufacturing facility at Vereeniging, in Gauteng province, boasts a 35 000 tonne annual production capacity and is equipped with the latest automated forging equipment from leading German and Italian suppliers. Plants on-site include three forge presses, two ring mills, CNC vertical borers, and heat treatment facilities for austenising, normalising, tempering, annealing and polymer quenching. The strongest 3 500 tonne press is capable of both open and semi-closed forging, and the ring mills’ capacity ranges from 200 mm to 4 500 mm outside diameter. DCD also has automated hardness and ultrasonic testing machines.
One large nozzle component weighs over three tonnes
Copper miner renews drill fleet Zambian copper mine Kansanshi has opted to renew its fleet of blast hole drill rigs, even though it’s facing tough times in the country. The new fleet will consist of Sandvik D25KS and DP1500i drill rigs. Rob McMaster, key account manager, First Quantum Minerals Sandvik Zambia, says that the mining contractor, First Quantum Mining & Operations (FQMO), has taken the decision to renew the DR500 fleet with new drills that are easier to maintain and operate on-site. “We work closely with our customers to ensure operations are run optimally at all times. When circumstances change and a mine’s requirements are altered along with it, we do our utmost to restructure equipment and fleets in such a way that the customer’s new needs are met. This is precisely what we have done at Kansanshi, where we are proud to deliver a solution that is tailored to Kansanshi’s current and changing future requirements. The new drill rigs are machines that will require less maintenance and specialised care than their predecessors.” Thanks to its compact size, proven design and durable power groups, the Sandvik D25KS blast hole drill is a very stable and highly manoeuvrable surface drill for surface mining and large-scale quarrying. The D25KS is a down-the-hole (DTH) hammer drill with a high-pressure air compressor, air-line lubricator and fine feed control. It is commonly used in large mining operations globally with a choice of hole sizes from 127 mm to 172 mm. The DP1500i is an intelligent, self-propelled, self-contained, crawler-based surface drilling rig equipped with a cabin, movable boom and a rod changer. It is ideal for production drilling in large quarries or open-pit mines and construction work sites. It is also well suited for wall control (pre-split drilling) and development works. The rig can be customised to meet special customer requirements.
In sid e M in in g 1 0 | 2016
39
events
Open mining conversations
T
HIS YEAR’S Joburg Indaba will
This year’s speakers include: • Trevor Manuel, former Minister of Finance • Neal Froneman, CEO, Sibanye Gold • J oseph Mathunjwa, president, AMCU •M ike Teke, president, Chamber of Mines SA • J acques Erasmus, global head: Mining, KPMG •P iet Viljoen, chairman, Regarding Capital Management •P eter Steenkamp, CEO, Harmony Gold •H RH Kgosi Pilane, king of the Bakgatla-ba-Kgafela nation •A ndile Sangqu, executive head, Anglo American SA
once again bring the mining industry together to have bold and frank discussions.
It provides an opportunity to cover various topics and challenges with both government and investors. Local and international speakers, fund managers, analysts and captains of industry will gather in Johannesburg to outline the way forward. The indaba also presents the chance to share insights into global commodity market prospects and investment opportunities.
Some of the conversation topics will include: •H ow will the South African mining industry become internationally competitive and attract the right investment to secure its future? •W hat should the mining industry be doing to make itself a key driver of the economy? •C ommentary on the challenges and solutions outlined above •W hat are CEOs actually doing to attract investment into the future of their companies and the industry? • S afety: how good (or bad) are we really? •T he mining industry: taking charge of its future
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