MBA September/October 2023 by miningbusinessafrica

ANNIVERSARY 1 9 9 4 - 2 0 2 4

5-8 February 2024

CTICC, Cape Town, South Africa

Since 1994, Investing in African Mining Indaba has been among the best places for deal sourcing and corporate matchmaking for the African mining industry. It serves as the most comprehensive meeting for investment, finance, innovation, and transformation to support end-to-end value creation. Today, Mining Indaba continues to drive the economic and sustainable development of Africa and the mining sector forward. Join us from 5-8 February 2024 to celebrate how far the industry has come and discover what the future holds for Africa’s mining industry.

HIGHLIGHTS OF MINING INDABA 2023

8100+ Attendees

900+ Investors & Dealmakers

500+

Mining Companies Executives

60+

Heads of State & Ministers

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25+

Ambassadors & High Commissioners

CONTENTS

September - October 2023

Editor’s Note

Political Instability Eroding Investor Confidence As of now, military coups have occurred in Guinea, Burkina Faso, Niger, Gabon, and Mali.

14 Cover Image: Carl Hamm PPS COVER STORY: PG 02 A Partnership Powering African Mining

Carl Hamm PPS and Düchting Pumps have collaborated to offer reliable cutting-edge solutions for dewatering to clientele in the African mining sector. Düchting Pumps brings into the partnership over 80 years of experience in the delivery of pump technology, while Carl Hamm decades of offering turnkey dewatering solutions.

ust when you thought resource-rich countries in West Africa were finally getting their acts together, pitifully, they are reverting to their self-destructive tendencies. Two years ago, these resource-rich countries seemed to be pulling out all the stops, relatively speaking, in creating a favourable environment to attract investment, especially in Mining, Oil and Gas. This was evident through foreign companies expressing interest in carrying out exploration and mining projects, as well as companies with operations in those countries outlining plans for Greenfield and Brownfield projects. Doubtless, there was no better gauge of investor confidence than this. However, presently, a series of military coups threaten to erode investor confidence which was growing. This could result in projects in the pipeline being put on hold, potentially resulting in significant revenue losses for the host countries. As of now, military coups have occurred in Guinea, Burkina Faso, Niger, Gabon, and Mali, and there is no prize for guessing that more will take place before year-end. Typically, coups trigger counter-coups as power struggles ensue within military governments. What a crying shame to witness that many resource-rich countries are yet to fully realise the full economic potential of their abundant resources. Let us hope for a return to sanity and stability soon.

Nick Barnes

editor@miningbusinessafrica.com

TEAM Editor Nick Barnes editor@miningbusinessafrica.co.za +27 10 055 3356 Web/Sub-Editors Jimmy Swira Jimmy@miningbusinessafrica.co.za + 27 10 055 3356

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COVER STORY

A Partnership Powering African Mining Carl Hamm PPS and Düchting Pumps have collaborated to offer reliable cutting-edge solutions for dewatering to clientele in the African mining sector. Düchting Pumps brings into the partnership over 80 years of experience in the delivery of pump technology, while Carl Hamm decades of offering turnkey dewatering solutions.

What sets the pumps apart is their adaptability to various operating conditions

ypically, African mining is known for its diverse landscape, which presents unique challenges when it comes to water management. Thus, efficient water management plays a pivotal role in the success of operations. That’s why, in response to the increasing need for dependable dewatering solutions in the sector, Carl Hamm PPS has strategically aligned with Düchting Pumps, a renowned German pioneer in pump technology. Together, the two companies are making waves in the mining sector, providing tailored and innovative solutions that have set new standards for quality and efficiency. They offer tailored products and services for open-pit and underground mining operations.

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Durability, performance, and adaptability Düchting Pumps brings over 80 years of experience to the table, a testament to its commitment to excellence. Its pumps are renowned for their durability, performance, and adaptability to the harshest mining conditions. With a focus on continuous improvement and innovation, Düchting Pumps has set the gold standard in pump technology. The HPXL, HPXM, and HPXU pump series offer exceptional performance and versatility for a wide range of applications. With a nominal pressure capacity of up to 160 bar and an impressive flow rate of up to 3,500 m³/h, these pumps are engineered to handle demanding tasks.

The pumps operate at a low speed, resulting in reduced wear and extended lifespan

What sets these pumps apart is their adaptability to various operating conditions. They are available in almost all metallic materials, ranging from cast iron to Super Duplex, ensuring compatibility with diverse liquids and environments. The selection of high-quality materials guarantees durability and reliability, even when dealing with abrasive content. The 4-pole design of these pumps is specifically engineered to handle liquids with abrasive elements, making them ideal for applications where wear resistance is crucial. They can efficiently manage liquids with a maximum density of up to 1,400 g/l, such as brine, and are well-suited for mining applications with up to 5% by weight (approximately 50,000 ppm) solids content. Additionally, these pumps operate at a low speed, resulting in reduced wear and extended lifespan. In summary, the HPXL, HPXM, and HPXU pump series offer robust, highperformance solutions designed to meet the demanding requirements of various industries, from mining to specialised fluid handling applications.

Seamless integration, comprehensive solutions Without a doubt, one of the standout features of this partnership is the seamless integration of Düchting Pumps’ cutting-edge technology into Carl Hamm’s turnkey solutions. Whether they need reliable mine dewatering, effective slurry transport, or wastewater management, Carl Hamm PPS and Düchting Pumps provide comprehensive solutions that streamline processes and optimise efficiency. In the mining industry, where downtime can be costly, the reliability of equipment is paramount. So, Carl Hamm PPS and Düchting Pumps understand this. Their joint offerings reflect their unwavering commitment to quality. Each pump is engineered with precision and

undergoes rigorous testing, ensuring that it meets the highest standards, enabling pump availability at all times. A shared vision of innovation and excellence As the African mining industry evolves, Carl Hamm PPS and Düchting Pumps are poised to play a more significant role. With a shared vision of innovation and excellence, their collaboration will continue to deliver cutting-edge solutions. Together, they are well-resourced to meet the ever-changing demands of African mining operations by driving progress and ensuring sustainable operations. The two companies are excited about prospects in the industry.

A powerful synergy Small wonder, Carl Hamm PPS, with decades of experience in providing turnkey solutions, recognised Düchting Pumps as the perfect partner to enhance its dewatering offerings. This collaboration has yielded a powerful synergy, allowing the two highly regarded entities to combine their strengths to serve Africa’s mining sector better.

Mining Business Africa | September - October 2023 3

Adopting Clean Coal Technologies (CCTs)

The High Cost of ‘Clean‘ Coal Power Plants Despite their envisaged benefits, adopting Clean Coal Technologies (CCTs) in new coal-fired power entails bearing a significant cost burden. Are organisations willing to bite the bullet? By Nick Barnes the need for a maximum amount of energy with minimum waste production while increasing the overall plant efficiency. But the question is: Are industries willing to go the extra mile for the sake of achieving the collective good in the long term? Would economics allow them? First of all, it is important to analyse the options available, and the commitment to adopting them entails. Available CCT options So far, three main CCTs deployed and operational globally are High-Efficiency, LowEmission, or HELE, pollution abatement, and carbon capture utilization and storage (CCUS) technologies. Boundary Dam Power Station Unit 3 in Canada: The world’s first operating coal-fired power plant to implement a full-scale post-combustion carbon capture and storage system.

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To keep global warming to no more than 1.5°C – as called for in the Paris Agreement – emissions need to be reduced by 45% by 2030 and reach net zero by 2050.” This is the pledge by the United Nations’ Net Zero Coalition on Climate Change. It is a clarion call for everyone to play a part in reducing greenhouse emissions from their respective activities. However, there is a huge burden on industries that utilise huge volumes of fossil fuels, as they are classified as the biggest producers of emissions. Coal-fired power plants Coal-fired power plants are one of the biggest producers of greenhouse gases. Greenhouse gases emitted by coal-fired power stations include but may not be limited to SOx, NOx, CO2, and particulate matter (PM). And so, industries that utilise or own coal-fired power plants should adopt measures to reduce emissions. The reality In an ideal world, industries should ditch coal and adopt the cleaner options of renewables and

nuclear. Nonetheless, the reality is that coal is still the main source of the world’s electricity. Based on the state of affairs, coal will remain a significant source of electricity in the foreseeable future. This is not least in South Africa where coal-fired power plants supply baseload electricity. On the role of coal, the World Coal Association could not have put it more perfectly by stating: “It is not the use of coal but the way coal is used that should be the focus of attention.“ In other words, the world has to use coal responsibly with minimal impact on the environment. It is now or never. Currently, in many countries, South Africa being one of them, coal-fired plants are approaching the end of their life about to be decommissioned. As a replacement, new plants will be developed. Thus, there should be more urgency. Clean Coal Technologies (CCTs) Thanks to recent advances, in new coal-fired power plants Clean Coal Technologies (CCTs) can be incorporated, where applicable, to minimise emissions. In the power generation context, CCTs refer to technologies that meet

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1. HELE The scope of ‘clean coal’ has been extended to include supercritical and ultra-supercritical coal-fired plants. Also known as High-Efficiency Low-Emission (HELE) plants, characteristically, these are without CCTs and run at 42-48% thermal efficiency. Compared with a subcritical unit, typically, HELE plants typically cost more than a subcritical unit on average. For instance, the capital cost of ultra-supercritical (USC) HELE technology is 20-30% more than a subcritical unit. However, this is offset by higher efficiency which reduces emissions and fuel costs to about 75% of subcritical plants. Usually, a supercritical steam generator operates at very high temperatures and pressures (above 22Mpa). This is a stage where the liquid and gas phases of water are no longer distinct. Countries that demonstrate that supercritical and ultra-supercritical plants are workable are South Korea and Japan. In these countries, about 70% of coal-fired power comes from supercritical and ultra-supercritical plants. 2. Pollution abatement There are several techniques employed in the abatement of coal. These include: • Washing coal Cleaning coal by washing aims at reducing

emissions of ash and sulfur dioxide when burning coal. • Electrostatic precipitators and fabric filters Electrostatic precipitators and fabric filters can remove 99% of the fly ash from the flue gases • Flue gas desulfurization The process of Flue gas desulfurization aims to reduce the output of sulfur dioxide to the atmosphere by up to 97%. This is dependent on the level of sulfur in the coal and the extent of the reduction. Coal at a site in South Africa

• With Low-NOx burners With Low-NOx burners, coal-fired plants can reduce nitrogen oxide emissions by up to 40%. When used together with re-burning techniques, Low-NOx burners can reduce NOx by 70%. Furthermore, when used with selective catalytic reduction, low NOx burners can clean up 90% of NOx emissions. • Integrated gasification combined cycle (IGCC) Integrated gasification combined cycle (IGCC) and pressurized fluidized bed combustion (PFBC) enable higher thermal efficiencies still up to 50% in the future. • Pulverised coal Ultra-clean coal (UCC) Pulverized coal Ultra-clean coal (UCC) from new processing technologies reduces ash below 0.25% and sulfur to very low levels. This implies that pulverised coal might be used as fuel for very large marine engines, in place of heavy fuel oil. So far, there are at least two UCC technologies under development. However, wastes from UCC are likely to be a problem. 3.

Carbon Capture Utilisation and Storage (CCUS) Carbon Capture Utilisation and Storage (CCUS) encompasses gasification and sequestration. Using steam and oxygen, gasification, including underground coal gasification (UCG)

in situ, turns the coal into carbon monoxide and hydrogen. Sequestration refers to the disposal of liquid carbon dioxide, once captured, into deep geological strata. Cost burden It is tempting to ask: Why doesn’t industry go all out in embracing these CCTs considering the urgency? Well, as with any business, in adopting the CCTs, the first consideration is cost and benefit – The board would be thinking: “What impact will it have on the bottom line? What is in shareholders Return On Investment?” The fact: based on evidence from projects, well-meant efforts to implement the CCTs may not always have the much-desired end. The World Coal Association notes this in its review: “Some of these (CCTs) impose operating costs and energy efficiency loss without concomitant benefit to the operator.“ Specifically, there is concern that in the quest to adopt the CCTs, the cost of achieving low, near-zero emissions would negate the economic competitiveness of coal. Generally, CCT technologies are both costly and energyintensive. Slow uptake Small wonder, in its Energy Perspectives, the International Energy Agency (IEA) laments the slow uptake of CCS: “CCS is advancing

slowly, due to high costs and lack of political and financial commitment.“ Meanwhile, as the world dithers to adopt CCTs, coal emissions worsen global warming. Unquestionably, the sooner commercial-scale technologies are embraced, the better. Realistic option Accordingly, the IEA urges timely interventions, especially the available CCTs. While owners of coal-fired power plants doubt the commercial viability of adopting CCTs, the IEA sees a realistic option in CCUS. The body hopes to see owners of coal-fired power plants embracing CCUS to put the world on the path to net-zero emissions. In a report on CCUS in its Energy Technology Perspectives 2020 series, it explains: “It is the only group of technologies that contributes both to reducing emissions in key sectors directly and to removing CO2 to balance emissions that cannot be avoided” (i.e. including direct removal of CO2 from the atmosphere).“ Enabling environment More importantly, governments have to play a pivotal role by creating an enabling environment for industry to fully embrace CCTs. One of the options is through tax breaks. To offset the financial losses due to the perceived liability of compliance, governments can incentivise industries by providing tax breaks for companies adopting CCTs.

Mining Business Africa | September - October 2023 5

Tyre Pressure Monitoring System for Small-to-Medium-Sized Operators

Revolutionary Tyre Pressure Monitoring MICHELIN MEMS LITE is Michelin Tyre Company’s latest entry-level Tyre Pressure Monitoring System (TPMS). It meets the contemporary needs of small-to-medium surface mine operators and contractors with smaller dump trucks. So far, recent data gathered from a gold mine in South Africa shows that, when deployed as specified, the MICHELIN MEMS LITE system increases tyre life, enhances safety and optimises productivity. Boldened by the results from the mine and emerging from other projects globally, Michelin is eager to replicate this success in the African mining sector.

ne of the pervasive challenges encountered in surface mining operations is dump truck downtime. Poor tyre pressure monitoring is often cited as one of the main causes. Given that material from dump trucks is needed in comminution processes, among others, from a productivity viewpoint, downtime can have a huge impact. For instance, tyre damage resulting from poor monitoring can ground a dump truck. The ensuing loss of productivity can translate into a huge revenue. The need for sound tyre pressure monitoring For this reason, it is paramount for mining companies to invest in sound tyre pressure monitoring systems (TPMS). Blue-chip entities, with huge financial resources, can afford the most advanced alternative technologies Unfortunately, with competing needs on their limited financial resources, small-to-mediumsized operators and contractors do not have that luxury. Hence, with no option, they stick to conventional tyre pressure monitoring. Timely Response Michelin, a global tyre solutions giant, recognises the need for affordable tyre pressure monitoring

among small-to-medium operators and contractor with smaller dump trucks typically below 150 tonnes. And so, in a timely response, recently, the company unveiled MICHELIN MEMS LITE, an entry-level TPMS which first went live in an African mine. In a brief to surface mine operators through Mining Business Africa, Fabien Taillardat, Mining Commercial Director for Africa, India, and the Middle East underlines the relevance of the revolutionary tyre pressure monitoring solution. Specifically, he explains that MICHELIN MEMS LITE addresses the shortcomings of the conventional technique of using a manual pressure gauge, which results in poor tyre monitoring and attendant challenges. He attributes this to its unique elements, particularly, the liquid-proof sensors and the reading station, which offer incredible convenience. Shortcomings of Conventional Pressure Monitoring The main shortcomings of the manual pressure gauge are limited interval usage, as well as inconsistency and unreliability. • Limited intervals Typically, a manual tyre pressure gauge

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is limited. Labour-intensive, it only allows an operator to monitor one truck per week. Furthermore, it is always a challenge for the tyre crew to track and access trucks without slowing production. • Inconsistency and unreliability A manual tyre pressure gauge is not consistent. “A manual manometer is not designed to measure the internal temperature of a tyre. Consequently, as the pressure of a tyre changes due to temperature changes, an inspector cannot accurately measure the changes and will have to rely on subjective perception,“ Taillardat expounds. Additionally, other shortcomings that cause unreliable and inconsistent tyre pressure monitoring are the calibration of the pressure gauge, continuous training of tyre inspectors, and the human error factor. Impact of Poor Pressure Monitoring Ultimately, the aforementioned shortcomings impact dump truck operations significantly. Markedly, this is in the areas of safety, accelerated tyre wear, and unscheduled downtime.

• Safety challenges Manual tyre pressure monitoring exposes the operator to poor vehicle handling and the tyre inspector to hazards around the trucks, including tyres with excessive pressure or heat build-up. • Accelerated tyre wear Poor tyre pressure monitoring leads to accelerated tyre wear. For instance, a 15% reduction in tyre pressure can reduce a tyre’s lifecycle by up to 20%, according to research data from Michelin. Worse still, a flat tyre that is not detected early can be damaged after a few kilometres. “This is a huge challenge on bigger dump trucks, where it is almost impossible for the operator to sense a flat tyre on the rear axle when they are driving,” Taillardat indicates. • Unscheduled Downtime Last but not least, poor tyre pressure monitoring pressure leads to unscheduled downtime. For instance, when a pressure problem reveals itself during an operator inspection, it usually has to be fixed immediately. This task halts production. Incredible Convenience of MICHELIN MEMS LITE In no doubt, it is not an overstatement that MICHELIN MEMS LITE introduces incredible convenience to tyre pressure monitoring, but fact. This is owing to liquid-proof sensors and a fixed reading station, which allow for control over tyre pressure monitoring, besides virtually eliminating the need for costly maintenance requirements. • Liquid-proof sensors The proven liquid-proof sensors that are included in MICHELIN MEMS LITE allow for the use of Tyre Additive. Taillardat stresses that this is not the case with most Temperature Pressure Monitoring solutions on the market. • A fixed reading station A fixed reading station strategically positioned on the side of the road captures tyre data periodically based on when vehicles drive. Worth underscoring, due to this feature, MICHELIN MEMS LITE does not require additional hardware on the truck. The feature makes the solution easy and inexpensive to deploy across the mine’s fleet. Reduced Maintenance Requirements The sensor and reading station has reduced the need for frequent maintenance, commonly encountered with comparable products on the market. The sensor has been designed to outlive the lifespan of the most durable tyres. This means that once installed inside the tyre, the sensor will stay alive until the tyre is disposed of. On the other hand, the reading station

is maintenance-free, save for some routine cleaning with regard to solar panels. Control over tyre pressure monitoring The combined efficiency of the sensor and reading station enabling control over tyre pressure-related issues. Taillardat elaborates, “Multiple readings per day per tyre – and at least once per day – allow operators to detect most pressure issues early enough to either fix them immediately or plan a stop at the tyre shop before the issue becomes critical.“ Massive gains By and large, through enabling timely intervention, MICHELIN MEMS LITE brings massive gains by enhancing safety and optimising productivity. From a safety perspective, MICHELIN MEMS LITE drastically reduces the time that tyre inspectors spend around trucks in the pit, which reduces their exposure to hazards. Further, health tyres minimise the risk of tyre-failurerelated accidents. In this way, it enhances safety. From a productivity perspective, MICHELIN MEMS LITE frees up staff from convoluted tyre pressure monitoring, allowing them to focus on other critical tasks, where they are needed. Additionally, a healthy tyre ensures that the dump truck is available for operations most times. Mine digitisation Indeed, all told, through the groundbreaking launch of MICHELIN MEMS LITE, Michelin demonstrates its commitment to helping smallto-medium mining companies digitise the critical but complicated process of tyre management. “The tyre is one of the few truck components that is still not connected. Thus, MICHELIN MEMS LITE is an easy way to connect tyres and gather data, paving the way for full digitisation of any mine,” comments Taillardat. Commitment to cutting-edge solutions Chiefly, the introduction of MICHELIN MEMS LITE denote Michelin’s solid track record in the provision of cutting-edge tyre management solutions. Michelin has been offering Temperature and Pressure Monitoring solutions designed for the extremely demanding mining environment for the past fifteen years. “Our extensive and global experience gives us an edge, allowing us to offer robust equipment that is easy to use and gives a consistent reporting suite that is professional and comes with the support of our field engineers,” Taillardat concludes, referring to Michelin’s capability to meet the contemporary needs of African surface mining sector sufficiently.

Milestone at a Gold Mine in Australia

here are several cases in surface mines that underline MICHELIN MEMS LITE’s efficacy in improving tyre performance, safety, and life. One of the most recent ones involves a gold mine in Australia, which significantly improved its pressure management. Relative to the previous situation, recent data indicates that the change has been considerable. In just six months, inflation that was widely spread between -12% and +5% around the ideal pressure at the beginning now is concentrated inside the manufacturer’s operating range between -5% and +5% of the ideal pressure. The improvement in pressure, which now complied with the manufacturer’s operating range, was translated into an increase in tyre life of roughly 8% more hours on each tyre. In a nutshell, if projected across the mine’s entire fleet, in financial terms, the savings add up to US$600,000 on the tyre budget, providing a return on investment in less than three months. Assistance in tyre installation

hen it comes to installation of TPMS, it is not uncommon that accounts of end-users are being left on their own. However, bending over backwards, Michelin does things differently. The installation is supervised by a Michelin field engineer who trains and assists mine staff through the following steps: •

Install the sensors in the tyres Michelin manufactures its tyres at 49” and above with a MEMS Ready rubber patch inside the tyre, allowing a tool-free installation with a simple Velcro strapping belt supplying with the sensors. Michelin supply rubber patches can be retrofitted inside non-Michelin tyres as well. Michelin will also be releasing very soon a magnetmount solution to attach the sensor to the rim. • Install the station(s) at a strategic location in the mine site The station is plug-and-play. Once the location is defined and the station is plugged to a power source (mine grid or solar panel/battery system), it starts emitting data through the 3G/LTE cell phone network.

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Wearable Technology for Enhancing Safety in Mining Operations

Wearables Revolutionalise Mine Safety Mine Health and Safety regulations obligate mine operators to adopt measures that mitigate the risks their employees are exposed to at the coal face of operations. That’s why they should continuously adopt tools that can help them enhance safety. Based on incredible abilities they display, wearables have staked their claim as a reliable part of health and safety solutions.

Miner’s smart helmet

urrently, mining companies are enjoying a spell of high commodity prices (long may it continue). This is despite high energy prices occasioned by the War in Ukraine and the lingering effects of the COVID-19 pandemic.

Mining Safety And Efficiency.” De Wet notes that 90 per cent of accidents are attributed to human error.

Market Trends and Challenges As you would have thought, mine operators are ramping up production to make the most of the favourable market conditions. According to project updates, Mining Business Africa regularly gathers, some are even moving their activities to deep-level areas, in some cases ultra-deep, as well as remote conditions, to access ore deposits. Inescapably, this increased activity in extreme environments exposes workers to escalated health and safety risks. For instance, amongst others, there is a likelihood of an increase in driving accidents. This is a fact that Cliff de Wit, Chief Technology Officer at Netstar (a subsidiary of Altron) highlights in this article, “How Advanced Technology Transforming

Generally, accidents result in financial losses of millions of dollars when downtime to production and compensation claims are factored in. Accordingly, mine operators must explore tools that can help them improve workplace health and safety. Role of Wearable Devices Expediently, wearable devices (or interchangeably as wearables) have emerged as one of the convenient tools that mine operators can utilise to enhance safety and improve productivity. Largely, this is thanks to the Internet of Things (IoT) and smart technology, which have opened up opportunities in wear technology. Until recently, the marvels of this innovation were regarded as the stuff of science fiction. What is more, as a tool, the portability of wearables is very convenient to the end-user. Worn on the user’s body, popular wearable devices include smart watches, smart glasses, smart helmets, fitness trackers, smart clothing,

A smart watch

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bands, wearable cameras, and RFID tags, just to cite a few. Basically, wearables come in different shapes and sizes for the end-user’s convenience. (It must be noted that the scope of this is widening). Diverse Features and Applications More importantly, it is their diverse features that make wearables fit for purpose. Usually, they are equipped with diverse features, specific to the application they are designed to serve. These include but are not limited to the following: GPS location, hazardous gas sensors, no-motion detection, and a panic button. These provisions improve communications through notifications and alarms. Due to their unique features, wearables are employed to reduce the risk of accidents and injuries (workforce safety and injury prevention), in addition to improving the efficiency of operations. Handily, the critical data generated from the devices informs decisions to be taken. Enhancing Workforce Safety and Injury Prevention From a workforce safety and injury prevention viewpoint, wearable devices allow intelligent perception of people, vehicles, objects, and other risks. For instance, driver-fatigue monitoring wearables devices provide alerts that warn of fatigue before it becomes a safety risk. In this way, it protects drivers and other road users. In case of emergencies, workers are removed from hazardous unforeseen. Moreover, it can be used to assess the health and safety risks faced. Then, based on that, companies can institute suitable training programmes for their employees, as well as adopt other safety measures. Ultimately, what are the gains from a health and safety perspective? Fewer events, lower investigations, and claims costs. A mine can’t ask for a better outcome to improve its health and safety initiative. Improving Productivity Through Wearables With wearables, efficiency can be achieved in two ways: real-time monitoring and inspection

of critical equipment, as well as resource scheduling. •

Real-time Monitoring and Inspection Wearables can be used in sound equipment maintenance. They can be used to inspect signs of failure in equipment to minimise downtime (increase availability for processes). To appreciate the value of wearables in sound equipment maintenance, take this example: imagine dispatching a team of technicians to attend to an issue at a remote mine. This task would entail huge expenses; conducting inspection and repairing equipment would consume more time. While this task is being taken, there would be downtime to equipment. Alternatively, the use of smart glasses or smart helmets would allow for reduced time and cost incurred in inspecting and repairing equipment. With wireless connectivity, a field engineer can receive expert guidance from the control centre in real-time. • Resource Tracking Wearable technology, like RFID tags into personalised hard hats, can be employed to efficiently track the workforce during mine

operations. For instance, assessing the time a worker spends on an assigned task. Additionally, the data can be used to map out ways of improving productivity through effective resource scheduling. RFID tags into personalised hard hats for each worker, providing mine supervisors at a monitoring centre with real-time information about their location and the state of the mine. The‘Next big thing‘ One may ask: Have we seen the peak penetration of wearables in the mining sector? Certainly not. A report compiled by GlobalData, Wearable Tech in Mining – Thematic Research, touts wearables as the ‘next big thing’ in mining. Indisputably, two factors substantiate this observation: recent developments in R&D, coupled with the increasing need for mining companies to improve safety. This suggests there is exponential growth in market demand. Already, there are indications that, with advances in research and development, the range of features of wearables is widening. Evidently, wearables are revolutionising safety in the mining sector, and the revolution is only beginning. It seems, the world hasn’t seen anything yet.

A mine worker with a smart arm band

Mining Business Africa | September - October 2023 11

With mining companies’ ultimate goal being zero harm, it makes sense for the industry to embrace smart technologies to improve mineworker safety by making it easier to identify and mitigate different risks. By Eulene Jones, Executive Head of Mining, Oil and Gas at Vodacom Business

Dry Stack Tailings Management

Meticulous Planning, Desired Output A specialist from Knight Piésold Africa states that detailed planning and thorough implementation of key elements in the dewatered tailings disposal process is essential to achieving the expected moisture content.

n the present mining atmosphere, cost, environment, and reputation are the primary factors influencing decisions on the tailings disposal technique employed. Regarding meeting these requirements, mounting evidence indicates that theviability of dry stack disposal (dewatered tailings) is increasing. However, attaining the desired residual moisture content threshold in dewatered tailings can be a complex task. Therefore, meticulous planning and effective implementation are crucial. This insight comes from Andrew Copeland, Technical Director (Mining) at Knight Piésold Africa, as part of the company’s regular updates to mining companies in a changing regulatory environment. Knight Piésold is a highly regarded international consulting company that offers

engineering and environmental services across the mining, power, water, transportation, and construction sectors. Achieving the Desired Moisture Content Drawing from Knight Piésold’s extensive experience in developing sustainable solutions for clients, Copeland is eager to advise mining companies on the practical approach of achieving the desired moisture content in dewatered tailings. Specifically, he highlights the following aspects: the impact of the fine fraction on dewatering; the significance of sampling tailings; evaluating dewatering systems during pre-feasibility; and the business case for dry tailings. 1. Fine Fraction (Clay Fraction) The fine fraction, particularly the clay fraction (presence of clay in tailings), determines the moisture content in dewatered tailings. Two common scenarios arise with tailings: one without clay presence and another with clay presence.

No Clay Presence Relating to moisture content in tailings without clay presence, Copeland expounds, “In tailings from hard rock sources where no clay is present, consistently achieving a filter cake moisture content of as low as 15% should be achievable with well-operated equipment.” • Clay Presence On the other hand, in cases such as weathered rock-originated tailings, kimberlite, or mineral sands ore bodies, clays can result in a moisture content of 30 to 40%. Generally, with these materials, achieving a filter cake moisture content of 30% residual moisture can be highly challenging, as Copeland indicates. Inevitably, this can lead to a substantial volume of water remaining in the tailings and being deposited on a dry stack. Given this challenge, some argue that the industry should refrain from labelling dewatered tailings as “dry stacks,” as liquefaction might still be possible. Thus far, this remains the bone of contention within the industry. 2. Sampling Tailings Due to the effect of the fine fraction on moisture content, Copeland emphasises the importance of obtaining tailings samples before designing the filter plant, transport system, and dry

www.knightpiesold.com 14 Mining Business Africa | September - October 2023

stack. This is because a slight change of 5% in moisture content could significantly impact the number and type of required filter units, the choice of transportation method, and the distinction between a stack that might liquefy or not (with or without compaction). 3.

Assessing Feasibility of Dewatering and Disposal Systems The feasibility of dewatering and disposal systems can be dictated by the cost of accessing water. For example, in situations where water scarcity is severe or water treatment is expensive, Copeland illustrates: “In semi-arid to arid climates where water is scarce, expensive, or obtained through seawater desalination, the drive to maximise water recovery through tailings dewatering is substantial. Thus, during the pre-feasibility stage of a project, the team must assess the feasibility of various dewatering and disposal systems.” The Business Case for Dry Stack Disposal From the above mentioned, the process of fully dewatering tailings to form a cake and transporting it to a “dry-stack” facility seems convoluted. One would ask: Why not dewater through high-rate thickeners and pump as highdensity slurry to a wet disposal facility? There could be a business case for the latter from the cost perspective. In response to this, Copeland refers to a recent study the Knight Piésold’s team conducted. The team examined the merits of both wet and dry disposal facilities. The results highlighted the relevance of the dry ‘stack disposal’ facility in ensuring that tailings disposal at a mining company ticks all necessary boxes in sustainable lifecycle. Copeland states that it is important to look beyond cost to appreciate merits of the

dry stack disposal technique. “The dry stack disposal option is costly but appealing due to water-related factors (cost, environment, and reputation). On the other hand, the wet disposal option is cost-effective but must be weighed against water permits or high supply costs,” he explains. On the intermediate option of paste (very high density slurry) disposal could be another option. However, it is often less favourable due to cost and operational challenges, potentially not significantly better than the high-density case. This reinforces the relevance of dry-stack disposal. Engaging an experienced consulting firm Overall, given the intricacies involved in achieving the desired moisture content in dry stack tailings, Copeland stresses the importance of engaging an experienced consulting firm that can coordinate all the specialist parties. “An

experienced consulting firm can provide a range of advice, design experience, with the support of other parties. This is advantageous for a client who would otherwise have to solicit specialised work from multiple parties and tender processes. Responsibilities are distributed between parties, and a consultant with a wealth of experience can apply insights from one project to another. Quick consultations with colleagues for advice and internal peer reviews are invaluable, particularly when cost-effective risk mitigation is crucial. GISTM stipulates that while an EoR (Engineer of Record) may be an individual, having a company or team to support that individual is equally important due to skill shortages and the need for an EoR to oversee multiple TSFs.” The team at Knight Piésold are dedicated to developing relevant solutions for comprehensive dewatered tailings disposal for clients in various mineral commodities in Africa.

www.knightpiesold.com Mining Business Africa | September - October 2023 15

Dry Stack Tailings Management

On GISTM Compliance and ESG Reporting

dopted after the Vale Brumadinho Dam disaster, the 2020 Global Industry Standard on Tailings Management (GISTM) sets a benchmark for safe tailings facility management, striving for zero harm. In the context of contemporary design, construction, and management of Dry Tailings Storage Facilities (TSF), an inherently complex task, Andrew Copeland, Technical Director of Knight Piésold, explains, “While GISTM covers the entire spectrum of good tailings management practices, its primary focus is on ensuring the safety and stability of facilities. It offers specific guidelines for assessing failure modes, the risk of liquefaction, and brittle behaviour.” Many clients recognise the need for compliance. One notable response is the shift away from designing upstream tailings dams, even though dry-stack facilities are designed and constructed in an upstream manner. Alternatively, clients acknowledge that buttressing of TSFs might be necessary and more cost-effective than building new ones. ESG Reporting Compliance with GISTM and ESG reporting go hand in hand. Adhering to GISTM standards can enhance a mining company’s ESG (Environmental, Social, and Governance) score Knight Piésold (Pty) LTD Reg. No. 1995/012742/07 1 Discovery Place, The Ridge, Sandhurst, Sandton, Gauteng, South Africa,2196

reporting. Regarding ESG reporting, the following are the primary areas of focus: reducing water consumption, minimising environmental impact by controlling seepage through geochemical testing and barrier system design and siting TSFs away from communities or downstream infrastructure and land use. Grey Area However, one aspect of ESG that is often overlooked is energy consumption. Thus far, this remains a grey area, laments Copeland. “The process of tailings dewatering, whether through vacuum or pressure filtration, demands significant power, which is typically not accounted for. Hence, if the power source is fossil fuels, air emissions offset gains in water recovery.” Knight Piésold specialises in tailored solutions to manage the complexities trade-offs. Copeland notes, “We can conduct trade-off studies and collaborate with vendors to assess entire systems, not just isolated components of the disposal chain. This is crucial, and GISTM highlights the importance of life-cycle design and costing, particularly closure design. KP can handle design, permitting, environmental aspects, and closure considerations.”

PO Box 221, Rivonia, 2128, South Africa T +27 11 806 7111 | F +27 11 806 7100 E Sandton@knightpiesold.com

On how the impact of IoT on TSFs management

ig data and the Internet of Things (IoT) have brought forth incredible efficiencies from exploration to mine closure and rehabilitation. Concerning tailings storage facilities, Copeland observes that, in recent times, one of the greatest areas of advancement have been online and remote instrumentation, as well as satellite monitoring (movement in particular). Online and remote instrumentation has opened a wide range of opportunities in the sphere of monitoring. “The installation of automated monitoring devices in tailings dams such as piezometers, inclinometers, water levels, rain gauges, flow rates and many others, with alert levels, allow for hourly or daily dashboards to be generated and updated (depending on reporting requirements or status). These dashboards provide immediate indicators of any change/ deterioration in integrity and can be reacted upon as per the Trigger Action Response Plans (TARPs).” The opportunities for unlocking more data from satellites is being explored, especially changes in moisture content that may be an early warning of instability (coupled with movement monitoring). However, Copeland believes that it is only a matter of time before advances in this area open further opportunities.

www.knightpiesold.com

Agitators and Mixers for Mining Projects

Mixtec’s role in lithium projects Agitators have taken centre stage in the lithium market, and Mixtec is at the forefront of this transformation.

n the ever-evolving mining industry, where innovation plays a pivotal role, Mixtec shines as a pioneering force. With a forward-thinking approach, the company proactively foresees forthcoming challenges and expertly tailors solutions to tackle them headfirst. Notably, Mixtec has been diligently tracking the constantly changing mining landscape, with a keen emphasis on the impressive advancements occurring within the lithium sector. The global demand for lithium has experienced unprecedented growth, fuelled by its widespread use in diverse applications, from powering electric vehicles to fuelling consumer electronics and storing renewable energy. As this demand surges, the role of agitators in the lithium market has taken centre stage, and Mixtec is at the forefront of this transformation. Historically, agitators have played a crucial role in the extraction and processing of lithium. New Lease of Life for Old Equipment

Mixtec has established itself as an industry frontrunner in the provision of agitators for lithium extraction processes as Mixtec already has large quantities of Mixers currently working in Lithium applications in multiple regions, including North America, South America, and Australia. Working closely with these customers, Mixtec has harnessed unmatched expertise in the different lithium processes, positioning themselves as the undisputed Market leader. In an interview with Mining Business Africa, Mixtec reiterates its commitment to clients stating that, “With a rich legacy spanning four decades and a proven track record, Mixtec is the natural choice to enhance your lithium operations. Our global presence further amplifies the advantages we offer our customers, guaranteeing top-tier solutions, regardless of your location.”

ixtec agitators offer a guarantee of energy savings, reduced stress on gearboxes, and decreased carbon losses in C.I.P. plants. As a leading supplier of industrial agitator and mixer technologies, Mixtec is enthusiastic about participating in mining projects launching in African nations, anticipating a surge in product demand. Mixtec is actively engaged in both novel agitator applications and the replacement of outdated, inefficient systems for mining operators. The company has earned a reputation for its reliability, innovation, and excellence in these specialised fields. Mixtec is strategically focusing on expanding its presence in retrofit solutions, actively raising awareness among potential clients.

the-art wet-end technology. Mixtec’s approach to providing practical retrofit solutions is founded on the principle of “Why replace it when you can restore it?” In line with this philosophy, the company frequently replaces various impeller systems by exchanging the blades and rejuvenating the shaft and couplings.

Delivering cost-effective solutions Mixtec’s cost-effective retrofit solutions involve upgrading existing mixer drives with state-of-

Return on Investment In the end, Mixtec’s approach ensures a return on investment from two crucial perspectives. These include achieving energy savings within just a few months and reducing stress on gearboxes while minimising carbon losses in C.I.P. plants. Looking ahead to its involvement in new projects, Mixtec emphasizes this philosophy in a statement, “We are dedicated to delivering the best possible solutions to breathe new life into old equipment, ensuring it operates at optimal performance levels.”

Mixtec's Projects in Australia

Mixtec’s Retrofitting a Game Changer for South African Mine

etrofitting is always done for two reasons, to solve a problem and to save costs. And this was no exception at a local mine in Gauteng, where the Mixtec team encountered a recurring problem with competitor products: equipment was failing prematurely. In response, the team took action by replacing twenty two wet ends with Mixtec’s superior mixing technology. This resulted in an upgrade to the drive systems. Notably, this intervention not only rectified the issue of equipment failures but also substantially improved solid suspension, all while reducing power consumption costs. Encouraged by this groundbreaking success, the customer subsequently requested a further enhancement to unlock the full potential of the drive and amplify production rates.

Mixtec, the market leader in Lithium applications!

www.mixtec.com info@mixtec.com 011 974 7161

With over four decades at the forefront of industrial mixing technology, Mixtec stands unrivalled in advancing lithium operations worldwide. With mixers already in operation in North America, South America, and Australia. Mixtec already has the experience and knowledge to advance your lithium operations.

Mining Business Africa | September - October 2023 17

Valve Solutions for African Mines

Efficient flow, robust valves Correct decisions in valve selection guarantee efficient liquid flow in pipes. Robust valves are the recommended for demanding needs of African mining projects.

Increase in mining activity has created demand for valves

ew underground mines have come on stream in some regions in Africa, following the completion of Greenfield projects. In addition, Brownfield projects, involving mine expansion, are progressing at various stages of completion. All the more, indicating that the trend is for a long haul: new projects are continually unfolding.

association focusing on suitable valves specific to mining requirements in Africa, customised solutions, and the growing role of remote monitoring. The member organisations have previous experience in the African mining sector. Thus, in their own right, they are authorities on continental trends.

Demand for valves This increase in mining activity has created demand for essential equipment used in mining operations, including valves. Some members of the South African Valve Manufacturers Association (SAVAMA) are keen to be involved in the supply of various valves to cater for various needs. Recently, Mining Business Africa sent a survey to ten member organisations of the

Suitable valves Usually, in mining, valves control the flow of high-pressure, abrasive and corrosive slurry in pipes. Thus, they have to be robust and perfect to ensure that the flow is smooth and efficient. This means the material of construction should have a suitable level of resistance. Customised turnkey solutions However, it is one thing to identify suitable valves

18 Mining Business Africa | September - October 2023

that are robust, and entirely another to tailor solutions for diverse operations. The suppliers of valves are cognisant that mines operate in different conditions. For this reason, they engage clients in customising solutions to devise solutions specific to their unique needs. One of the processes in customising entails rigorous testing to ensure that the valve supplied meets or surpasses industry requirements. Deliberately, this approach ensures that valves meet required standards and exceed client expectations. Comprehensive and convenient, turnkey delivery of solutions is generally preferred. More or less, the turnkey solution covers everything from the initial enquiry, design, supply and installation, to maintenance advice to ensure increased uptime and satisfaction.

Remote valve management is allowing mining companies to benefit from valves delivered through a customised turnkey approach. Remote valve management for remote operations The rise in remote management, facilitated by the Internet of Things (IoT) and artificial intelligence, have transformed valve management in remote mining areas. These have eliminated the need for on-site manual inspections, which are difficult, time-consuming and potentially expose the personnel deployed to hazards. Two of the most groundbreaking innovations are smart valves and remove actuators and control panels. • Predictive maintenance Smart valves with data analytics capabilities actively monitor and regulate flow rates, detect faults in real-time and predict maintenance requirements. In this way, it improves performance while reducing downtime. • Centralised management Remote actuators and control panels enable centralised management. This reduces costs, enhances safety and eliminates the need for on-site personnel.

Groundbreaking strides Clearly, innovations, including IoT and artificial intelligence integration, design enhancements, and materials innovations, indicate groundbreaking strides in research and development efforts. This is especially evident through the increased role of IoT and artificial intelligence, design enhancements and materials innovations. These innovations meet the need for increased efficiency, enhanced safety and sustainability in the application of valves.

Onus on end-users All told, the onus is on end-users. Bearing in mind the critical role of valves in mining operations, it is advisable that end-users exercise due diligence. Rigorous assessement of both the product and the supplier’s integrity is paramount. So, selected valves must demonstrate superior performance, through smooth operation and reliable slurry management. There should be no half measures in product selection.

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Mining Business Africa | September - October 2023 19

Lubricant-enabled reliability (LER) solutions

Return on Investment of Good Lubrication Management WearCheck’s Lubricant-enabled reliability (LER) solutions boost the lifespan of mining equipment.

ondition monitoring specialist company, WearCheck, appreciates the value of a world-class lubrication maintenance regime, which goes a long way towards keeping mechanical parts operating at their full capacity, for longer. In line with the company’s ongoing innovation, WearCheck extends its services to offer expert advice on, and insights into, lubrication-related products and maintenance techniques that can go the extra mile towards keeping oil in an optimum state. Solving machine lubrication issues This advice is dispensed through WearCheck’s Lubrigard division, where a team of industrial lubrication specialists focuses on solving machine lubrication issues as part of WearCheck’s lubrication-enabled reliability (LER) offering. Some of the products featured in WearCheck’s Lubrigard brand include varnish removal systems, vacuum dehydrators and filtration systems for specific applications. Lubrigard manager for WearCheck, Chris Hattingh, explains how good lubrication management can help to boost an operation’s return on investment in condition monitoring. ‘We arrange our LER services around FLAC - that is fuels, lubricants, air and coolants. In the mining industry, for example, some of the problematic commodities could be diesel, or oil and grease, or air, or coolant, where potential contamination is negatively affecting performance. ‘Our Lubrigard technicians are positioned to improve the reliability of these commodities and keep the mining machinery running optimally. We conduct a full FLAC audit, recommend standardisation techniques and help our customers to implement a road map to achieve lubrication best practice. ‘In any industrial operation, all assets have a particular risk rating, depending on factors ranging from operating conditions, component age, environmental issues and more. Using our FLAC systems, we can put controls in place to reduce the risk of that asset from high to low. ‘Moreover, the scientific oil analysis data enables us to implement systems to mitigate assets’ risks. Therefore, ongoing oil and other fluid analysis helps not only to diagnose the underlying problem, but also to track the effectiveness of remedial action that has been taken.

the proper management of lubricants and fluids. This methodology acknowledges the pivotal role that lubricants play in safeguarding the functionality of mining equipment. LER goes beyond traditional maintenance practices by integrating predictive and preventive strategies centred around lubrication.

Chris Hattingh of WearCheck’s Lubrigard division, advises customers on the use of products and tips that can help keep fuel clean and enhance their condition monitoring programme. This service forms part of the company’s lubrication-enabled reliability (LER) offering.

Tried and tested LER techniques Hattingh advises customers on lube management in many sectors, including mining. ‘In the dynamic and demanding world of mining, the reliability and performance of equipment are paramount to operational success. Mining operations involve heavy-duty machinery that operates in harsh conditions, subjecting them to extreme temperatures, dust, water, and heavy loads. To ensure smooth and efficient mining operations, maintaining the health of these machines is vital. A cutting-edge approach to achieving this is through tried and tested LER techniques.’ Understanding lubricant-enabled reliability LER is a comprehensive approach to equipment maintenance that focuses on optimising the performance and lifespan of machinery through

20 Mining Business Africa | September - October 2023

The significance of FLAC Hattingh explains that the company’s FLAC (fuels, lubricants, air and coolant) system is the answer to boosting reliability of mining equipment. ‘FLAC, WearCheck’s reliability improvement programme, focuses on one or all of the commodities we use in our equipment that, if not in an optimal state, will have negative mechanical impacts that will affect our clients’ business operations - either through production losses, reliability issues or expensive component replacement costs.’ FLAC is an essential element of any total fluid management (TFM) approach. In the mining sector, where downtime can lead to significant financial losses, TFM becomes a strategic asset. TFM is the broader framework within which lubricant-enabled reliability operates. It encompasses the entire lifecycle of fluids within mining machinery, from selection and application to monitoring and disposal. TFM involves careful consideration of additional factors such as contamination control, fluid analysis, and disposal practices. Key Components of LER • Lubricant selection: Choosing the right lubricant for each mining application is crucial. Different components of mining equipment, such as engines, transmissions, and hydraulic systems, have varying requirements. High-quality lubricants with appropriate viscosity and additives help reduce friction, wear, and heat generation, thereby enhancing equipment performance and longevity. • Contamination control: Mining environments are notorious for their dust and debris, which can infiltrate lubricants and accelerate equipment wear. Implementing robust contamination control measures, such as effective filtration systems and regular fluid sampling, prevents abrasive particles from causing

•

damage and extends the life of both fluids requires skilled personnel. Training and machinery. maintenance teams in the intricacies of Fluid analysis: Monitoring the condition fluid management, analysis interpretation, of lubricants and fluids through regular and maintenance best practices is analysis provides insights into equipment essential for the strategy’s effectiveness. health. Fluid analysis involves measuring WearCheck offers an extensive range of parameters like viscosity, acidity, and the training courses aimed at all levels within presence of contaminants. By tracking an operation, from employees ‘at the changes over time, maintenance teams can coal face’ to senior management. Many identify potential issues before they lead to of WearCheck’s courses earn delegates costly breakdowns. continuing professional development (CPD) Predictive maintenance: The real points. Courses are run on site for clients value of LER lies in its ability to enable around Africa or in scheduled venues. predictive maintenance. By analysing For more information on WearCheck’s fluid data trends, WearCheck’s training schedule, please visit https://www. experienced diagnosticians can predict wearcheck.co.za/training.html when components might fail and advise maintenance teams to schedule Benefits of LER for mining maintenance during planned downtime, operations minimising unscheduled interruptions to • Increased equipment lifespan: mining operations. Implementing LER practices extends Proactive measures: LER promotes a the operational life of mining equipment. proactive approach to maintenance, Reduced friction and wear, as well as focusing on preventing issues rather than proactive maintenance, result in fewer reacting to them. Regular inspections, equipment failures and replacements, adherence to manufacturer guidelines, leading to significant cost savings. and scheduled fluid changes based • Enhanced equipment performance: Proper on condition instead of fixed intervals lubrication leads to improved equipment contribute to sustained equipment efficiency and performance. Mining reliability. machinery can operate at optimal levels, WCKand Mining Business Africa 180x130 copy.pdf 1 2023/05/17 delivering 10:40:14 Training expertise: Successful higher productivity and better implementation of an LER programme operational output.

Condi�on monitoring is KEY to mining produc�on

•

Minimised downtime: Predictive maintenance based on fluid analysis allows for planned maintenance downtime, minimising unexpected breakdowns that can halt mining operations and lead to financial losses. Reduced maintenance costs: LER reduces maintenance costs associated with premature component failure. Regular fluid analysis and proactive maintenance prevent the need for extensive repairs or replacements. They also reduce the need for having to purchase expensive emergency spares. Environmental responsibility: TFM ensures proper disposal of used fluids, reducing the environmental impact of mining operations. It promotes responsible fluid usage and disposal, aligning with sustainability goals.

Sustaining success in a competitive landscape Lubricant-enabled reliability has emerged as a game-changer in the mining industry. By recognising the pivotal role of lubricants and fluids in equipment health, mining operations can achieve increased reliability, improved performance, and reduced operational costs. As the mining sector continues to evolve, embracing these advanced maintenance practices can be the key to sustaining success in a competitive landscape.

WearCheck, Africa's leading condi�on monitoring company, is commi�ed to serving the mining industry with its range of sophis�cated analy�cal techniques. Our specialist oil, coolant and fuel tes�ng programmes allow customers to reduce maintenance costs, avoid unexpected mechanical failures and ul�mately reduce unscheduled down�me.

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Tes�ng and Analysis | Lubricant-Enabled Reliability | Asset Reliability Care Mining Business Africa | September - October 2023 21

Air Compressor Solutions for Mining Projects

Strong Product Line-up Spurs Sales Having expanded its range of air compressor solutions, Integrated Air Solutions is targetting further growth.

An ELGi compressor range is available at Integrated Air Solutions

ince taking over as MD of Integrated Air Solutions in October 2022, Wayne Jacobs has been building sales focus on the company’s extensive range of ELGi, FS-Elliott and recently secured ABC Compressor ranges. 25 years of experience With more than 25 years’ experience in the compressor industry with some leading international brands, Jacobs recognises the opportunities for the range line-up in just about every industrial sector. His scope of experience ranges from small-scale manufacturing and assembly businesses to heavy engineering, railway and allied sectors, agriculture, food and beverage, automotive and process industries. “Our renowned ELGi range is supplemented by our exclusive distributorship with FS Elliott in the USA. This means that there isn’t a compressor application that we can’t meet with machines with a worldwide reputation for performance and longevity, proven in our harsh operating conditions” Jacobs says. ELGi’s compressed air solutions ELGi has a complete range of compressed air solutions: oil-lubricated and oil-free rotary screw compressors, high-pressure diesel-driven rig compressors, oil-lubricated and compressors and centrifugal compressors, portable

compressors, dryers, filters and downstream accessories. “The ELGi range is ideally suited to our Southern African climate having been tried and tested here for over 25 years in our harsh environment,” Jacob explains. Partnership agreement FS-Elliott The recent signing of a partnership agreement with leading North American air compressor

MD of Integrated Air Solutions, Wayne Jacobs

22 Mining Business Africa | September - October 2023

manufacturer, FS-Elliott, has extended Integrated Air Solutions’ capabilities to include the supply of spare parts, service and plant upgrades to the local existing installed base of FS-Elliott centrifugal oil-free compressors. Pennsylvania-based FS-Elliott is a global leader in the field of centrifugal air compressors with their Polaris® industrial compressed air range. The company offers a reliable flow of oil-free air to ISO 8573-1 Class 0 from 900 cfm to 12 000 cfm, and their groundbreaking PAP PLUS engineered series flow capabilities of up to 24 500 cfm. PET market niche “We’ve also identified potential growth in Southern Africa for high-pressure oil-free compressors used in PET bottle blowing applications and concluded a distributor agreement with ABC Compressors who specialise in this market segment. These Spanish manufactured machines have been providing sales and service in virtually all countries worldwide for more than 80 years,” elaborates Jacobs. “The well-respected ABC range also has applications outside of the food and beverage sector too, including natural gas, petrochemicals, aerospace, water treatment and biogas industries.”

Rental Division Integrated Air Solutions‘ rental division comprises a range of electric and diesel portable compressors to meet the needs of customers who prefer the benefits of renting over purchasing. The division can offer customers reliable temporary solutions while they wait for their existing compressor to be replaced or repaired. “This approach ensures that our customers have the highest up-time, productivity and return on their rental investment,“ states Jacobs. The company’s rental fleet consists of the following units: • Electrical compressors from 7.5kW to 250kW with pressures from 7 – 10 bar • Diesel compressors from 185cfm to 1 100cfm with pressure ranging from 7 to 10 bar • High-pressure diesel compressors – 21 bar with a flow of 1 100cfm Jacobs affirms to clients Integrated Air Solutions’ commitment, “We service each compressor in-house before the unit leaves on its next hire and offer skilled compressor technicians to support our customers’ service needs on site. “Our rental options offer fast, flexible, costand energy-efficient, and reliable industrial air supply for planned contingencies or unexpected emergencies. Rental is the ideal solution for industrial shutdowns, short-term construction

Integrated Air Solutions caters for customers who prefer rental over purchasing

and civil works, and annual shutdowns in mines and refineries,“ he adds.

refurbishment centre in Witfield in Boksburg and via the branch in Durban.

Service, service, service The reality in business is that: No matter how good and reliable a machine is, if the product isn’t well supported by qualified technicians and plentiful spare parts backup, then its reputation quickly fades. That is why, Integrated Air Solutions has invested heavily in ensuring customers have ready access to these services both on-site and through its repair and

New branch in Cape Town Integrated Air Solutions always strives to bring its air compressor solutions to the customers’ doorstep. It will have a branch in Cape Town soon. “Strong growth in Western Cape industries dictates that we will soon be opening a sales and service facility in Cape Town to cater for rapidly increasing demand in that region,” Jacobs reveals.

FS-Elliott centrifugal oil-free compressor

Mining Business Africa | September - October 2023 23

Air Compressor Solutions for Mining Projects

Integrated Air Solutions

Integrated Air Solutions is a specialist compressed air solutions provider dedicated to delivering air reliably and efficiently, helping companies achieve their productivity targets by keeping the total cost of ownership of their compressed air low. With access to a widely diverse portfolio of premium brand products, Integrated Air Solutions offers a broad range of innovative and technologically superior compressed air systems, parts, services and turnkey solutions for the mining, pharmaceutical, cement, petrochemical and general industrial market segments. Our offerings include oil-lubricated and oil-free rotary screw and piston compressors, centrifugal compressors and diesel portable

compressors. We provide upstream and downstream air treatment solutions such as refrigerant and desiccant driers, air receivers and filters. Our product portfolio comprises the ELGi range of compressors, FS-ELLIOTT oil-free centrifugal compressors, ABC Compressors for the PET industry, and AIRCOM aluminium piping systems. Our exper t service teams are trained to maintain and support all brands of air compressors. We overhaul and service air ends, refurbish complete compressors and undertake professional air audits and pipe installations. Our innovations include MethaSperse – patented technology that significantly reduces dust propagation and associated risks in underground mining applications. When it comes

24 Mining Business Africa | September - October 2023

to providing engineered high-pressure diesel compressor packages, Integrated Air Solutions is the unrivalled market leader, having supplied customised solutions for the water-well drilling and mining industry for decades. Our rental division comprises a range of electric and diesel portable compressors to meet the needs of customers who prefer the benefits of renting over purchasing, and to support our sales division where we are able to offer our customers reliable temporary solutions while they wait for their existing compressor to be replaced or repaired. This approach ensures that our customers have the highest up-time, productivity and return on their rental investment

Friction (Koepe) winding installations

The Electro-mechanical multi-rope clamping and lifting device The use of a Clamping and Lifting Device (CLD) for rope handling significantly simplifies a wide range of maintenance and service work on friction (Koepe) winding installations.

LD’s simultaneously clamp all the ropes in one winding compartment without any significant preparation work required beforehand. The CLD is able to pull down in the case of an upwards load, or lift in the case of a downwards load. Introduction The CLD configuration (shown in Figure 1) with electrically driven lead screws and manually engaged rope clamps differs from the automated hydraulic CLD design: • The linear actuation is achieved by utilizing lead screws instead of hydraulic cylinders • The rope clamps are manually positioned and not hydraulically engaged and disengaged • The system sequencing and general operation is manual as opposed to fully automated and monitored. The electro-mechanical configuration has the capability to equal the stroke length of the standard hydraulically actuated CLD design however it boasts a significantly lighter weight (weighing approximately 9 t), has fewer moving parts and no hydraulic components; all resulting in a simple, cost-effective, low-maintenance machine. The suspension beams are designed to engage with all the ropes simultaneously, or one at a time. wheel bearings, winder bearings and rope tread liners. The multi-rope CLD is designed to be located in the headgear below the upper deflection sheaves. The device is self-contained and can be moved from the parked position to the engaged positions and back by means of a geared ‘hand crank’.

Application By using the CLD, suspended loads can be removed from the head ropes and attachments of a chaired conveyance, thus creating slack rope by lifting (pulling upwards) the rope in the compartment opposite the chaired conveyance. Due to the travel range of the upper suspension beam, up to 1 700 mm of slack rope can be created with each stroke. This allows for the servicing of ropes, rope attachments, sheave

Description The manually engaged rope clamps can be inserted in both sides of the suspension beams, thus allowing the CLD to be engaged with both compartments of the Koepe hoisting system. The rope clamping wedge inserts slide in tapered wedges machined into the beam such that the clamping force on the rope is proportionally intensified as the rope pulling force is increased. Refer to Figure 2 for a diagrammatic representation.

Figure 2

The lower of the two identical suspension beams is rigidly mounted in the CLD frame, while the upper beam can be moved vertically between the guides while driven by the lead screws. The

Mining Business Africa | September - October 2023 25

Friction (Koepe) winding installations upper suspension beam accommodates the lifting and lowering operations. It is moved by means of two electrically powered synchronized lead screws that can comfortably travel at 2.5 m/min under a full load of up to 650 kN. The lead screws are driven by an electric motor through a self-locking worm gearbox complete with an additional fail-safe brake arrangement. During operation, the CLD will be securely anchored to the headgear structure by means of clamps and/or anchor bolts to prevent lateral movement.

Operation The winding ropes are clamped on the upper suspension beam and pulled upwards by means of the rotating lead screws. Upon completion of each stroke, the rope clamps are manually engaged in the fixed suspension beam. The movable suspension beam is then moved slightly downwards, transferring the load to the clamping wedges in the fixed suspension beam. The movable suspension beam now becomes load free and allows for the manual removal of its

wedges before moving to its original position for the start of the next cycle. Wedges are removed using small jacks mounted on a common rail powered by a manually operated hydraulic pump. Though this is a manual process this sequence can be repeated as many times as needed.

Tehnical data table

General applications of the CLD

Advantages of Electro-Mechanical CLD • Lower capital cost option when compared to the fully automated hydraulic CLD • Lower maintenance costs when compared to the automated hydraulic CLD • No hydraulic power pack is required

•

HEAD OFFICE 1st Floor, Osborne Office Suites, 4 Osborne Lane, Bedfordview, 2007 South Africa PO Box 3037, Bedfordview 2008, South Africa, Tel. +27 11 383 9300

Figure 3 describes the lifting sequence.

Figure 3

• • •

Clamping and lifting of multiple steelwire ropes suspended in a friction winder mine shaft compartment Lifting and lowering the maximum loads within a hoisting compartment Creation of slack rope (for removal of pins, or removal of ropes from the winder drums and sheaves Accurate positioning of conveyances during rope-up or rope-changing operations.

26 Mining Business Africa | September - October 2023

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We offer our clients a comprehensive service including design, manufacturing, supply, installation, commissioning and site servicing of winders, winches, hoists, sheaves, rope-handling and related equipment. Our single point of contact service provides seamless interfacing between all disciplines and covers all major equipment brands.

OUR DIVISIONS MECHANICAL

As an independent systems integrator for shaft hoisting systems, we have extensive systems engineering and project management experience. Our service includes planning, mechanical design and construction of winders and various systems. We satisfy clients' hoisting and general industrial requirements with custom-designed solutions.

AUTOMATION, DRIVE TECHNOLOGY AND SYSTEMS INTEGRATION

We provide full engineering, manufacture and supply of all electrical aspects for legacy as well as modern winders including drive, control and safety systems for all winder types and all rope handling equipment. Our products cover fully automated as well as manual control systems, brake control systems and cage and level-control systems and can be provided as retro-fit or new equipment. Our extensive systems integration experience enables us to incorporate electrical, mechanical and hydraulic equipment of all makes.

HYDRAULICS

We design, manufacture, install, commission, maintain and refurbish a variety of hydraulic systems for industrial and mining applications. A comprehensive range of specialist hydraulic products and related services is available. We offer our clients individually tailored solutions in compliance with applicable standards and regulations.

SITE SERVICES AND SPARES

Our experienced, in-house Services Department personnel manage and execute the site work required to install and commission both new and refurbished winders as well as carry out site upgrades, emergency breakdown repairs and maintenance work. We also offer Level 1 dynamic braking and cage accelerometer inspections as well as annual inspections of hoisting systems.

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Associated Energy Services (AES)

Optimised Steam Generation AES is putting the benefit back into ore beneficiation for mines through optimised steam generation.

Beneficiation processing in mining is heavily reliant on energy inputs, including steam for thermal energy supply.

fficiency, reliability, maintenance, sustainability, fuel selection and procurement are just some of the challenges facing the mining sector – and, as one of South Africa’s leading operations and maintenance service providers to the steam and boiler sector, Associated Energy Services (AES), is perfectly placed to optimise these. “Our ability to deliver efficient steam generation is based on reliability and the continuity of operation as well as on the cost of production. Any improvement on production costs through reduced fuel usage will definitely have a positive operational and financial impact,” says Dennis Williams, Commercial Director, AES. Superior energy from steam Steam is an important and useful energy carrier. Within the mining context, the energy generated from steam assists with everything from downstream ore beneficiation and specialist mining processes, to on-site cooking and heating for mineworkers’ accommodation. “Typically, while a mine’s steam plant is operating and supplying steam, there is little concern. However, few mines operate their steam generation facilities with the same care

as their core production equipment. Hence, this aspect of their operations and maintenance tends to lag behind the others - and this is where AES can assist,” he says. Experienced assistance AES’s experience encompasses many aspects, including operational efficiencies and maintenance planning, shut down maintenance and supplementing the often limited steam boiler operation skills pool available to mines in remote locations. Efficiency and productivity are key deliverables specified as part of its service level agreements – topped off with a performance guarantee for which the company is well-known. Furthermore, Williams says that AES takes pride in partnering with clients to create bespoke solutions based on their specific operational challenges and objectives. Health, safety and sustainability “25 years of experience in working with potentially dangerous pressurised steam and combustion plant means we have an inherent awareness of - and focus on - safety. Our ISO 9001, 14 001 and 45 001 certification

28 Mining Business Africa | September - October 2023

demonstrates how we can contribute to the optimised operations and maintenance in sectors such as mining,” Williams states. Another area where mines are under particular pressure is sustainability and environmental impact. Once AES understands a client’s objectives – whether it is reducing costs related to sustainability, mitigating these costs completely or even as the greenest choice in its market – the viable options can be addressed. New reserves and operations Many mines want to open new reserves and explore new operations - but they are constrained as the national energy utility is not always able to supply them with sufficient power. In this case, AES will recommend and propose standalone power generation solutions to allow mines to develop such opportunities. “Potential clients in the mining sector will soon see just how far-reaching taking something like steam generation out of their scope of management - and letting AES look after it - can be. They will also see how the benefits flow from that upstream to their beneficiation process,” Williams concludes.

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Self-regulating heating cables for process pipes in mining

Uninterrupted Process Pipe Performance Cape Town-based, Energi Solutions at Africa offers customised Thermon Self-Regulating Heating Cable solutions to clientele in the African mining sector. In the latest industry-specific update, the company’s Team of Application Engineers guarantee that the cable solution ensures uninterrupted Process Pipe Performance. significantly, unscheduled downtime,“ deduces the Team Head.

n the heart of the mining industry, where operational efficiency is paramount, maintaining optimal process pipe temperatures is critical. Unfortunately, conventional heating cables pose numerous challenges, impeding pipe availability, and risking costly downtime. Energi’s alternative solution In response to this challenge, Energi Solutions at Africa offers the practical alternative of Thermon self-regulating heating cable solutions for process pipes. The company’s solution involves designing, engineering, supplying and installation, above and beyond support. Tapping into their vast pool of experience, the team of application engineers can devise and deliver the best possible solution personalised for the client. A Compelling Business Case In an industry update, through Mining Business Africa, the Team Head stresses the compelling business case for mining companies to adopt tried and tested Thermon self-regulating cable solutions for their process pipes. Firstly, he highlights the inherent challenges of conventional (traditional) heating cables and how they impact pipe performance, then

demonstrates how self-regulating cables fill the gap. Challenges of Conventional Heating Cables and their Impact Typically, the mining sector operates in diverse and often harsh environments, subjecting equipment and infrastructure to extreme conditions. Unfortunately, traditional heating cables, although useful, come with their own set of limitations, the Team Head points out. One of the primary issues experienced with traditional cables lies in their inability to adapt to varying heat demands along the length of a pipe, leading to energy wastage and uneven temperature distribution. This inefficiency can result in operational disruptions, as sections of the pipe might overheat or, worse, succumb to freezing temperatures. Moreover, conventional heating cables lack the self-regulating capability that is vital for maintaining a consistent temperature. This deficiency can lead to overheating, which not only increases energy consumption but also jeopardises the integrity of the pipes. “Inefficacies like these can compound over time, leading to reduced equipment lifespan, higher maintenance costs, and, most

30 Mining Business Africa | September - October 2023

Necessity of Self-Regulating Heating Cables As an alternative solution, self-regulating heating cables have proved to be effective. Thermon self-regulating heating cable brand is highly esteemed worldwide across industries as one of the solutions that meet all the requirements. The Team head confirms that the breakthrough self-regulating heating cables have completely transformed the way mining operations approach process pipe temperature control. This is based on the company’s feedback from clientele supplied with the solutions.“These cables are engineered to adapt to the actual thermal requirements of the pipe, eliminating wastage and ensuring precise, uniform heating throughout the entire length. The self-regulating feature empowers the cable to automatically adjust its heat output based on the surrounding conditions, maintaining a consistent temperature regardless of fluctuations in ambient temperature.“ In the long run, by embracing selfregulating heating cables, mining operations can eliminate uneven temperature distribution and the associated risks. For instance, it has been established that the innovation not only enhances safety but also optimises energy consumption, translating into substantial cost savings over the long term. In particular, with the Thermon self-regulating cable solution in place, process pipes remain consistently operational, leading to increased overall efficiency and productivity. Meeting Demand in Mining Energi Solutions at Africa self-regulating cable solution is just what mining companies need in the current operating environment As energy efficiency has become central to mining operations, there is a noticeable surge in demand for self-regulating cable solutions for process pipes. Handily, Energi Solutions at Africa is at the forefront. The company is always keen and well-resourced to offer energy solutions that align with the sustainability goals of modern mining operations through Thermon’s self-regulating cable solution. “The

self-regulating heating cables are designed to operate efficiently, utilising only the necessary energy required to maintain the desired temperature. This energy-saving approach not only reduces operational costs but also contributes to a greener, more environmentally conscious mining operation,“ illustrates The Team Head. Customising Solutions for Mining and Related Sectors Energi Solutions at Africa’s commitment to delivering tailored solutions is evident in its approach to designing self-regulating heating cable systems for mining and related sectors. It recognises that every operation is unique, and so heating requirements can vary widely based on factors such as pipe diameter, material, ambient temperature, and flow rate. Consequently, Energi Solutions at Africa is committed to providing the client with relevant self-regulating heating cable solutions that ensure optimal performance and the highest efficiency level. It follows a meticulous process when customising solutions for its clients, entailing Assessment and Analysis; Engineering and Design; Installation and Commissioning; and Ongoing Support and Monitoring. • Assessment and Analysis The Team of application engineers conduct a comprehensive assessment of the client’s mining operation, thoroughly analysing the existing process pipes and heating infrastructure. This step allows for a clear understanding of the specific challenges and requirements. • Engineering and Design Drawing from years of experience and cutting-edge engineering expertise, Energi Solutions at Africa team designs a customised self-regulating heating cable system

that precisely matches the client’s respective operational needs. This includes determining the optimal cable type, length, and distribution, as well as integrating advanced control mechanisms. • Installation and Commissioning The customised solution is meticulously installed and commissioned by Energi Solutions at Africa’s skilled technicians, ensuring seamless integration into the existing infrastructure. Subsequently, rigorous testing and quality checks are conducted to guarantee flawless operation. • Ongoing Support and Monitoring Energi’s commitment goes beyond installation. The company provides continuous support and monitoring, ensuring that the self-regulating

heating cable system operates at peak performance throughout its lifecycle. This proactive approach minimises potential issues and maximises uptime. In the dynamic world of mining operations, downtime can translate into substantial financial losses. Conveniently, Energi Solutions at Africa‘s self-regulating heating cable solution has emerged as a practical alternative. By addressing the limitations of conventional heating cables, specifically proving to be a technology that can adapt to real-time temperature demands, the solution has ushered in a new era of process pipe temperature control. Empowering mining companies With its energy-efficient approach and unwavering dedication to customisation, the Team of application engineers at Energi Solutions at Africa ensure that their Thermon self-regulating heating cable solution empowers mining operations to optimise efficiency, reduce costs, and ensure uninterrupted performance.“Choose Energi Solutions at Africa’s self-regulating heating cables and unleash the full potential of your mining operation,“ the Team Head urges mining companies to explore the effectiveness of Thermon self-regulation cable solution. Experience the future of process pipe temperature control with Thermon’s self-regulating heating cables – where innovation meets efficiency, and operational excellence becomes the new norm in mining. Energi Solutions at Africa www.thermon.co.za salessa@energisolutionsafrica.com Contact: +27 217628995 Mobile: +27 823363552

Mining Business Africa | September - October 2023 31

Submersible Pumps for Mine Dewatering Projects

Clog-resistant, low-maintenance and Long-lasting Submersible dewatering pumps have proved to be an answer to irksome, intermittent pump failure. Incredibly, switching to a clog-resistant submersible pump eliminates the problem. Hidrostal Pumps South Africa is eager to provide relevant clog-resistant submersible pump solutions to mining companies.

his is the time when a high-revenuechasing mining company would loathe encountering pump failures in dewatering applications in the throes of productivity. Unfortunately, pump failure occurs when least anticipated, resulting in downtime and translating to losses in thousands of dollars from a profit perspective. Clogging - the bane of mine managers One of the common problems diagnosed in submersible pump failures is clogging, which is the bane of mine managers. Unfortunately, some interventions in pump failure tend to be ‘stop-gap’ measures. At some point after the interruption of work to remove the solids that have clogged the pump component, the issue resurfaces, effectively becoming a vicious cycle. Asked about how the industry can forestall the problem, André Nel, The Operations Manager of Hidrostal Pumps South Africa, explains: “It is all a question of choice. It is about choosing pumps that forestall the recurrence of the problem. It all boils down to the issue of choice. ‘We are products of the choices we make,’ so goes the saying. And submersible pumps are no exception.” Nel suggests that it is rational to use clogresistant submersible pumps in dewatering applications where clogging is naturally a big problem. This is based on evidence gathered

A clog-resistant submersible pump

from projects that Hidrostal Pumps has been involved in, solving complex problems that clients in different sectors, including mining, encountered. Clog-resistant submersible pumps He advises mining companies to consider switching to clog-resistant submersible pumps for their dewatering requirements to avoid downtime related to pump failure. Specifically, he refers mining companies to Hidrostal pumps, highlighting benefits that have endeared them to clients and made them the preferred option for clients in projects. Hidrostal pumps are specially tailored by Hidrostal’s team of professionals to be ideally suited for different applications, and highly respected for features such as robustness, simplified installation process and reduced maintenance costs. Robust Hidrostal pumps are fitted with a unique screw-centrifugal impeller, which makes them ideal for handling mediums that contain large solid content and fibrous material. Enhancing robustness, the impeller type enables the pump to be extremely clog-resistant, minimising downtime as a result of blockages. Furthermore, they have been engineered to adapt to specific needs or requirements and to ensure that pumps have long-extended life

32 Mining Business Africa | September - October 2023

expectancies. Nel comments on how the pumps meet all contemporary requirements expected: “We have various material combination possibilities that have been tried and tested, to cater for different pumped mediums and applications. Special protective features and elements for preventative maintenance and monitoring purposes ensure that pumps do not fail prematurely. With this process, we ensure that Hidrostal pumps are successful in difficult applications and that they achieve the best results concerning performance, energy efficiency, reliability, and low lifecycle costs. Furthermore, the manufactured seals from Hidrostal guarantee long service life.” Simplified installation and reduced maintenance costs The convoluted process of installation and maintenance requirements are common burdens in submersible pumps. Hence, Hidrostal pumps have been designed, engineered, and fabricated with alleviating these challenges in mind. For permanent installations, the guide rail mounting arrangement with automatic coupling simplifies the installation and retrieval of submerged units. This minimises the time required for inspection and maintenance. The adjustable entry cone and various material options are available for applications with abrasive and corrosive process fluid.

The team at Hidrostal Pumps South Africa is aware that it is one thing to provide mining companies with suitable clog-resistant submersible pumps and another to ensure that the pumps perform optimally as expected. Unwavering post-installation support One of the common concerns from contractors and mining companies is being left to their own devices when it comes to post-installation services. However, Hidrostal Pumps South Africa is unwaveringly committed to supporting clients. The team of application engineers is involved in the commissioning of pumps if the customers allow. “We offer our expertise and knowledge as a value-added service. We also offer postinstallation technical assistance. We supply pumps with a comprehensive manual, and all the technical backup that is required for smooth and problem-free operation,” Nel warrants. Opportunities in the resilient sector Hidrostal Pumps believes the mining sector will continue being resilient in the face of challenges in the world economy. Currently, mining companies are launching greenfield and brownfield projects, the team is eager and ready to serve the need for clog-resistant submersible pumps.

Synfuel Hidrostal Pumps since the 1980s

60 years of developing, manufacturing, and installing

f prospective clients need assurance of the reliability and durability of the Hidrostal pumps, they don’t have to look further: a Synfuel manufacturer has been a loyal customer of the Hidrostal pump brand since the 1980s. Doubtless, there can’t be a better illustration of trust than that! “We occasionally still get pumps sent in for repair that have been in operation for 25+ years. Other brands have been tried and tested, but Hidrostal is the pump that stood out above the rest and prevailed in terms of reliability and service delivery.” More importantly, proof positive that the pumps sell well, there is usually no interaction between Hidrostal Pumps and the mine’s engineering teams.

idrostal is a pioneer in pumping technology. For more than 60 years, Hidrostal has been developing, manufacturing, and installing pumping systems worldwide with a focus on wastewater and other challenging liquids with solid content. Since its establishment, high quality and continual commitment to improvements have formed the basis of the company. Hidrostal Pumps is constantly seeking ways of improving its products for a better customer experience. The company’s latest release or development in the Hidrostal Pump range is the TUMA motor.

Introducing the new Hidrostal TUMA submersible motor line The new Hidrostal motors are available with drive power from 15 - 60 kW and are suitable for vertical and horizontal installation. Thanks to the design with protection class IP68, the motor pumps can be used in permanent flooded operation, but also in dry installation. The cooling is ensured by an internal energy-efficient cooling circuit. The existing Hidrostal range of sub – and immersilble motors are still available, ranging from ‘0.1- 650kW. → non-clogging delivery → high suction capacity → gentle conveying due to low shear forces → high efficiency → stable characteristic curve → long service life

Hidrostal SA (Pty) Ltd 38 Kielboot Ave Laser Park Honeydew +27 11 704 5333 sales.za@hidrostal.com

→ low pulsation → continuous, speed proportional conveying → high pressure stability

hidrostal.com Mining Business Africa | September - October 2023 33

Electric-operated double Diaphragm (EODD) Pumps for Mining and Industrial Applications

A Revolutionary Energyefficient, Low-maintenance, Low Emissions Pump QUANTM stands as the pioneer and sole holder of a patent for an electrically-driven double diaphragm (EODD) pump featuring FLUXCORE technology – a transverse flux motor. This innovation empowers the QUANTM EODD pump to emulate the functional capabilities of air-operated diaphragm pumps (AODD). Notably, these advanced EODD pumps substantially curtail maintenance and energy expenditures associated with alternative positive displacement technologies, achieving remarkable reductions of up to 80%. The groundbreaking QUANTM pump is now accessible to potential clients within the mining and industrial sectors in Africa, facilitated by the expansive distribution network of Axflow AQS Liquid Transfer.

n the modern landscape of mining and industrial pumping, the focal points are centred around low maintenance, energy efficiency, and sustainability. Yet, the challenge lies in navigating the myriad positive displacement pump technologies, evaluating their pros and cons, and making judicious decisions that factor in initial unit costs, operational downtime losses, and the entire lifecycle expenses of the pump. Among these considerations, energy consumption emerges as a pivotal factor, an aspect in which the QUANTM EODD pump is profoundly advantageous. The Quandary of Selection William Human, the QUANTM Product Manager, offers insights when it comes to the advice sought by those in the mining and industrial

domains. He emphasises that inherent selfpreservation features, such as dry running capability, automatic self-priming, direct or remote flow control (adjustable from 0 to 50Hz), and a superior spares-to-unit cost ratio, serve as critical criteria for contemplating QUANTM for both current upgrades and future expansions within the realm of positive displacement pump systems. The Evolution of EODD Pumps While EODD pumps have been present in a basic form for some time, the design of the QUANTM pump presents a clear revolutionary departure. Tailored to meet the growing demand for clean energy and sustainable technology, the QUANTM pump stands out due to its distinctive design.

34 Mining Business Africa | September - October 2023

Human underscores the advantages that render QUANTM the most compelling option, citing simplified installation, reduced maintenance demands, and lower energy costs in comparison to other pump designs, including centrifugal, lobe, gear, progressive cavity, peristaltic, and piston/plunger technologies. Key Attributes The defining characteristics of QUANTM pumps centre around the self-priming diaphragm pump design and the Flux Core technology, both of which magnify the benefits of the innovation. Self-Priming Diaphragm Pump Design QUANTM’s self-priming diaphragm pump design incorporates a seal-less pumping chamber.

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Electric-operated double Diaphragm (EODD) Pumps for Mining and Industrial Applications and energy efficiency effectively drives down the total cost of ownership. The energy-related benefits are particularly noteworthy given the substantial role of energy expenses in mining and industrial operations. Furthering Sustainability QUANTM’s reduced energy usage translates to diminished emissions, aligning with the pursuit of reduced carbon footprints by organisations. Seamless Integration The QUANTM pump stands out with its ease of installation. Designed as a “plug-and-play solution,” it boasts features such as flexible connection options with existing rigid piping and utilisation of the current power supply. Commissioning the QUANTM pump requires no special precautions like priming or seal system protection.

This unique design allows for continuous dry runs without necessitating the replacement of stationary or rotating seals. Flux Core Technology Central to the QUANTM range of EODD pumps is the Flux Core – a transverse flux motor. This AC motor mimics the behaviour of a DC motor, obviating the need for a soft starter. The Flux Core motor delivers exceptional torque power, providing up to eight times more continuous torque at low speeds and power density compared to conventional motors. These attributes translate to minimized size and resistance losses. User Benefits QUANTM presents users in the mining and industrial sectors with an array of advantages: • Optimal Energy Efficiency • Reduced Maintenance Costs • Ultra-Low Total Cost of Ownership The benefits of reduced maintenance costs and a lowered cost of ownership stem from significant savings in spare parts expenditure. Notably, the wet side of the QUANTM EODD pump shares the same spare parts as the standard AODD pump range. The design inherently incorporates economies of scale and interchangeability, further enhancing cost-effectiveness. Additionally, the provided maintenance manual outlines preventative maintenance principles and regular intervals, contributing to prolonged pump lifespan and diminished maintenance expenses. The intersection of low maintenance costs

36 Mining Business Africa | September - October 2023

Versatile Applications With its multitude of features and inherent design advantages, the QUANTM pump finds utility across a diverse range of applications, encompassing underground mine face dewatering without compressed air, general water transfer, emulsion transfer, paint kitchens, water treatment facilities, sand bead milling, blending and transfer, chemical transfer, waste material handling, ingredient transfer, and adhesive transfer. The QUANTM EODD pump emerges as the foremost choice when confronted with the need for solutions that prioritise low maintenance costs, energy efficiency, and sustainability.

Enduring partnership, Guaranteed Expectations

hrough forging enduring partnerships, AxFlow AQS Liquid Transfer guarantees that the client’s needs with respect to positive displacement applications are met with QUANTM EODD pumps. Mining & industrial companies can collaborate with our team of technical experts for their unique solutions. Put a QUANTM on trial and see the results 1st hand. AxFlow AQS Liquid Transfer is the sole distributor for the QUANTM EODD range in South Africa. Other product ranges include AODD Pumps, Piston Diaphragm Pumps, Submersible Pumps, Heavy Slurry Pumps, Centrifugal Pumps, Solar Pumps, Vertical Multistage Pumps, Progressive Cavity Pumps and Peristaltic Pumps.

Earth-Moving Equipment for Mining Projects

Driving Safety, Sustainability and Efficiency The latest product releases indicate that OEMs are leaving no stone unturned in pursuit of innovations that meet all contemporary requirements – environmentally-friendly, safe, and efficient performance. 3.

Ergonomic Design and Operational Comfort Ergonomic design and operational comfort are prominent themes in earth-moving machinery. They aim to enhance the efficiency and safety of earth-moving machinery.

he earth-moving equipment space is never short of activity, regardless of the state of the global economy. Usually, OEMs always take a long-term perspective on their business, looking beyond crises. As it is panning out, recent reports indicate that major economies are recovering from the effects of the COVID-19 pandemic. Reflecting their confidence in the market, major OEMs are churning out different models of their respective equipment brands from their assembly plants. Three Earth-Moving Equipment Trends Mining Business Africa picked out three trends that stand out from reviewing factory-fresh earth-moving equipment releases:

1. Eco-friendly Equipment Environmental concerns and stricter regulations are shaping the new product development and upgrades of existing ones. For instance, the necessity to reduce noise pollution at sites, cut down emissions, and improve efficiency has prompted the shift towards electric and hybrid machinery and eco-friendly earth-moving equipment. 2. Integration of IoT and Data Analysis The integration of the Internet of Things (IoT) and data analysis has become core to equipment operations. These enable real-time monitoring, predictive maintenance, and sharper operational insights.

Pursuit of More ‘Greener‘ Alternatives In the main, there have been several aweinspiring innovations in the earth-moving equipment arena. Based on ongoing developments, certainly, OEMs are not resting on their laurels. They are aggressively investing in R&D endeavours to continuously drive toward optimal Safety, Sustainability, and Efficiency in their respective earth-moving vehicle brands This pursuit illustrates that every OEM is striving to distinguish itself from the pack. If that is what realising a ‘greener‘ environment would take, then it couldn’t be more perfect. Equipment Rental and Leasing There are several trends from the customer side. Notably, one of them is the growing popularity of renting and leasing earth-moving machinery for Small and Medium-sized Enterprises (SMEs) contractors and junior mining companies. They regard this as a more cost-effective alternative to bearing the high cost of purchase and maintenance. Through renting, organisations have access to highquality equipment without exorbitant initial investments.

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Mining Business Africa | September - October 2023 37

Collision Avoidance for Mining Vehicle Fleet

New Wabtec CAS Generation 3 Solution for Level 9 compliance Fifteen years of operations with no fatalities or unreported events prove Wabtec’s commitment to safety and reliability. The company further enhances compliance with the Earth Moving Equipment Safety Round Table (EMESRT) Level 9 vehicle controls.

abtec has launched a next-generation Collision Awareness (CAS) Generation 3 solution that represents significant advances in sensing accuracy, user experience, and EMESRT Level 9 vehicle controls. Implemented by mining solutions company, Probe IMT, across Southern Africa, this proven technology sets the standards for mining safety and is an ideal solution for mines striving to achieve their zero-harm goals. Thus far, fleetwide implementation is underway at key sites. ‘Game-changing performance and user experience’ CAS Generation 3 has been developed to provide game-changing performance and user experience,” says Gert Roselt, CEO of Probe IMT. “This breakthrough from Wabtec is the result of multiple years of field and production testing, leveraging the invaluable insights of Wabtec customers and the industry. CAS Generation 3 offers unique functionality and is the only system to include real-time health monitoring. Powerful intelligence delivers up to fifty times better alarm performance, compared to the market. Wabtec’s intensive production testing has ensured a lower nuisance alarms rate, meaning there is less impact on productivity.” Reducing critical vehicle interaction risk The Wabtec CAS Generation 3 solution is designed to reduce critical vehicle interaction risk through features including smart rules and

intelligence, remote monitoring, troubleshooting, 360-degree situational awareness, ultra-high accuracy sensing, productivity monitoring, machine data acquisition, critical vehicle interaction threat advisories, detailed reporting and analytics. The solution offers a user-friendly, intuitive interface and is fully configurable with adaptable settings to fit site-specific requirements. Roselt explains that recent rapid advances in technology, such as satellite positioning, LiDAR, intelligent vision systems and fatiguedetecting solutions, have all had a major impact on collision avoidance systems and the level of software that is available to mining companies. “With proper system integration and a wholeof-mine safety approach, mines can reap huge benefits from implementing high-performing solutions.” Wide-reaching benefits reported Besides collision avoidance, CAS Generation 3 users are already reporting wide-reaching benefits. “In an Australian coal mine, a Haul Truck operator reported unexpected CAS alerts from safe-passing. Poor haul road maintenance in wet weather conditions was found to have caused the haul road to narrow, reducing the haul truck passing gap. This could then be rapidly addressed,” says Roselt. “CAS Generation 3 analytics further identified machine operators working outside standard mine site procedures, allowing for a change in this risky behaviour.”

38 Mining Business Africa | September - October 2023

Enabling Level 9 CAS Compliance Level 9 Collision Awareness (CAS) vehicle intervention for both underground and surface mining became mandatory in December. “Compliance with Level 9 requires sophisticated CAS systems that provide high integrity object detection, operator warning and automatic intervention, when necessary, to prevent an accident. Companies that are not compliant must submit plans for achieving compliance. There is a strong need for future-proof solutions that can be rapidly implemented.” Proven track record While South Africa has over 30 CAS suppliers, varying from established providers to small new entrants, few can offer the proven track record of multinational players, says Roselt. “Mines should carefully select implementation partners and technology to ensure a smooth transition to Level 9. Wabtec solutions help our clients comply with Level 9 regulations, as well as avoid the pitfalls of sensing technology inaccuracies, unnecessary alarms during normal operations and reduced system availability that can impact production. Fifteen years of operations with no fatalities or unreported events prove Wabtec’s commitment to safety and reliability. We’re proud to be implementing these solutions in a rapidly evolving arena.”

Cutter fans

The Role of Cutter Fans in Pump Agitation Ruaan Venter, Business Development Manager at IPR - the official distributor of Toyo heavy duty slurry pumps in southern Africa, sheds light on the functions and applications of these components, offering valuable insights into their importance in pump systems.

he integration of innovative features during pump design has significantly enhanced performance and efficiency, with significant benefits for lowering total cost of ownership. One such component, the cutter fan, plays a crucial role in achieving effective agitation and solids handling. Ruaan Venter, Business Development Manager at IPR - the official distributor of Toyo heavy duty slurry pumps in southern Africa, sheds light on the functions and applications of these components, offering valuable insights into their importance in pump systems. Cutter Fans: Enhancing Agitation and Solids Handling The cutter fan, also known as an agitator, has revolutionised heavy-duty submersible dredge pumps. Toyo Pumps was the pioneering manufacturer to incorporate this type of agitation into its designs. Venter says that their patented curved three-blade stirring attachment, threaded

The cutter fan, also known as an agitator, has revolutionised heavy-duty submersible dredge pumps.

onto the pump shaft just below the suction inlet, became a gamechanger in handling solids-laden slurries. The primary function of the cutter fan is to dislodge and re-suspend solids, creating a slurry. As fluid flows towards the pump suction, the cutter fan redirects a portion of the fluid away from the pump, generating a fanning effect. This redirection and cyclic process result in a concentrated “pocket” of high solids content slurry directly in front of the pump suction inlet. This maximises the pumping efficiency and effectiveness, making it an essential feature for dredge pumps. To protect the cutter fan, a stand is attached to the bottom of the pump. For larger pumps, an additional stub shaft is placed between the pump’s main shaft and the cutter fan, providing extra protection and stability during operation. Differentiating Between Cutter Fans and Other Components During pump installation, it is crucial to differentiate the cutter fan from other components. Operating the pump with a reversed rotation can lead to unscrewing of components during operation, resulting in potential damages and costly repairs. To identify a cutter fan correctly, it is advisable to consult the pump’s rotational arrow. The cutter fan is easily visible and recognisable, as it pushes fluid away from the pump for agitation purposes. Observing the marked arrow during pump wiring ensures the correct rotation and installation of the cutter fan. Cutter fans have significantly contributed to the efficiency and effectiveness of pump systems, particularly in managing solids and enhancing agitation. With a deeper understanding of the roles played by the cutter fan’s ability to redirect fluid and maximise solids management exemplify the advancements in pump technology. By correctly identifying and using cutter fans, pump operators can ensure optimal performance and avoid unnecessary operational issues,” Venter concludes.

View of a Toyo pump’s cutter fan or agitator with a competitor’s agitator (black component) showing size comparison.

The cutter fan plays a crucial role in achieving effective agitation and solids handling during arduous pumping applications.

View of a Toyo pump’s cutter fan or agitator with a competitor’s agitator (black component) showing size comparison.

Mining Business Africa | September - October 2023 39

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Greater Recovery Better Grade

with Eriez Deep Field 3,500 Gauss Magnetic Wet Drums Optimize Your Roughing, Cleaning & Scavenging with Eriez Magnetic Elements & Tanks • Hybrid Rare Earth-Ceramic elements produce greater recovery in cobbing and roughing stages • Cleaning and finishing magnetic elements improve selective separation

Eriez.com .....

Advertiser’s index African Mining Indaba 2024................................................IFC

KSB Pumps and Valves Pty Ltd............................................19

AQS Liquid Transfer................................................................35

Michelin Tyre Company SA..................................................08

Associated Energy Services (AES).....................................05

Mixtec Pty Ltd..........................................................................17

Carl Hamm PPS.....................................................................02

Probe IMT Group...............................................................OBC

Energi Solutions at Africa......................................................30

PDAC 2024.............................................................................29

Eriez International...................................................................40

Tech4IR...................................................................................37

Hidrostal South Africa............................................................33

TMIF.......................................................................................IBC

Integrated Air Solutions..........................................................24

Vodacom Business.................................................................12

Invicible Valves........................................................................18

Wearcheck Africa...................................................................21

Knight Piesold Consulting......................................................14

Winder Controls.....................................................................27

Mining Business Africa (MBA) is Pan-African bi-monthly publication that focuses on latest developments in mining and allied industries in Africa. The publication covers the scope of critical activities from pit to port – mineral exploration (prospecting), mine planning and development, extraction, mineral processing, storage transportation, as well as beneficiation. Mining Business Africa provides the desired mileage for companies looking to promote their products and services to a specific niche clientele in the African Mining Sector. Subscribers are located or at least involved in projects in South Africa, Botswana, Zimbabwe, Zambia, Kenya, Democratic Republic of Congo, Kenya, Tanzania, Ghana and Nigeria. MBA is published by Media Icon, a company manned by personnel with a combined experience of 30 years in the publishing space.

TO ADVERTISE | CALL: + 27 10 055 3356 | Email: info@miningbusinessafrica.co.za

Organised By ENDORSED BY

25 - 26 OCTOBER 2023 JNICC, DAR ES SALAAM TANZANIA THE UNITED REPUBLIC OF TANZANIA MINISTRY OF ENERGY

Unlocking Tanzania’s Future Mining Potential

2000

700sqm

700

100

Attendees

Exhibition

Ministerial, Governmental & Industry Speakers

Networking Hours

Diamond Sponsor

Delegates

Countries Represented

Gold Sponsor

Bronze Sponsors

Exhibiting Companies

Conference Sessions

Silver Sponsor

ICT Partner

Supporting Partners

REGISTER AS A DELEGATE Contact: Nancy Mbogoro info@tanzaniamininginvestmentforum.com | +255 747 345893 | TanzaniaMiningInvestmentForum.com

MBA September/October 2023

Articles inside

Greater Recovery Better Grade

The Role of Cutter Fans in Pump Agitation

Collision Avoidance for Mining Vehicle Fleet New Wabtec CAS Generation 3 Solution for Level 9 compliance

Driving Safety, Sustainability and Efficiency

Electric-operated double Diaphragm (EODD) Pumps for Mining and Industrial Applications

Electric-operated double Diaphragm (EODD) Pumps for Mining and Industrial Applications A Revolutionary Energyefficient, Low-maintenance, Low Emissions Pump

TUMA submersible motor line

Submersible Pumps for Mine Dewatering Projects

Submersible Pumps for Mine Dewatering Projects Clog-resistant, low-maintenance and Long-lasting

Self-regulating heating cables for process pipes in mining Uninterrupted Process Pipe Performance

Optimised Steam Generation

Friction (Koepe) winding installations

The Electro-mechanical multi-rope clamping and lifting device

Integrated Air Solutions

Air Compressor Solutions for Mining Projects Strong Product Line-up Spurs Sales

Return on Investment of Good Lubrication Management

Efficient Flow, Robust Valves

Agitators and Mixers for Mining Projects Mixtec’s role in lithium projects

Meticulous Planning, Desired Output

Wearables Revolutionalise Mine Safety

Tyre Pressure Monitoring System for Small-to-Medium-Sized Operators Revolutionary Tyre Pressure Monitoring

The High Cost of ‘Clean‘ Coal Power Plants

A Partnership Powering African Mining