MINING MINING DEVELOPMENTS DEVELOPMENTS January/February 2015 Issue
MAGAZINE
Becker Mining South Africa - IGBT traction battery chargers Becker Mining South Africa's recently launched IGBT mine traction battery chargers have been designed to charge underground traction batteries in the shortest possible time, at the lowest possible temperature, to ensure optimum battery performance. Becker-igbt-traction-batterychargers…one Becker Mining South Africa's recently launched IGBT mine traction battery chargers have been designed to charge underground traction batteries in the shortest possible time, at the lowest possible temperature, to ensure optimum battery performance. “The most common causes of battery failure and reduced service life are associated with incorrect charging techniques,” says Andrew Trentelman, senior general manager: electronics, Becker Mining South Africa. “Becker Mining's new IGBT mine traction battery chargers, which utilise insulated-gate bipolar transistor (IGBT) technology for quick on and off switching, are more efficient and cost effective than conventional transductor controlled, oil-
cooled traction battery chargers. “These IGBT battery chargers are lightweight air cooled units, which are controlled by an intelligent micro processor circuit that acts as the main control computer, responsible for the logging, charge functions and controls. “Becker Mining's new chargers utilise Delta Volts/Delta Time (DV/DT) for the precise detection of a battery's gassing stage so the charger can terminate the second rate charge more rapidly. This technology, which prevents overcharging often associated with conventional battery chargers, ensures reduced charging times and lower power consumption. By reducing the charge current once DV/DT is reached, batteries are charged at a significantly lower temperature.” With an improved power factor of 0,8 and a maximum input current which has been reduced from 42 A to 32 A, these energy efficient battery chargers offer power savings up to 10 KVA during maximum output current. The auto cell detection system enables IGBT chargers to execute a short test charge on every battery to the determine the number of cells connected to ensure
correct charging. Other cell configurations and various Amp/hour ratings (100 A/h to 1 000 A/h) can be programmed and stored through the user interface, with no additional changes to the battery charger itself. For the efficient management of mine traction batteries, Becker Mining's robust chargers have an integrated power line communication (PLC) identification method, which automatically logs the serial number, as well as the charge history related to that specific battery. Becker-igbt-traction-batterychargers…two The user interface is a full colour display which provides relevant information, including voltage, current, state of charge, temperature of stack, capacity charged, duration of charge, errors, time and date. Becker Mining's IGBT traction battery chargers are equipped with Wi-Fi to facilitate future downloading of data, errors and the charge history of each battery, or for viewing or analysis on the surface. Becker Mining South Africa offers a technical advisory and support service to mines throughout Southern Africa.
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Published by: E.S.C Magazine T/A Projects Publishers 62, 2nd Avenue Houghton 2198 Johannesburg P.O. Box 92744, Norwood, 2117, Johannesburg, South Africa. Tel: +27 11 346 5053 Fax: +27 86 601 9195 Email: info@miningdevelopmentsnews.com Website www.miningdevelopmentsnews.com The Publisher does not accept any responsibility for the accuracy or authenticity of the contributions contained in the Magazine and advertisements. Views expressed by the contributors are not necessarily those of the Publishers. Š All rights reserved
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Keestrack - SA Crushing & Screening Equipment
Our Experience Your key to Success
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MOTION DETECTION IN MINING Motion detection in mining is the process of discovering motions in mining surfaces and slopes and thereby providing alerts for possible dangers. This process is made effective via the application of digital electronic cameras in conjunction with computer technologies that are characterized with computer software. With the computer, videos and data coordinated by the digital cameras are safely saved. The saved videos and data act as parameters towards providing the actual signals for warning against the possible mining danger to occur. The motion analysis software aids in calculation of parameters like distance, acceleration, velocity as well as angles of deformation. The same parameters can as well be used to design safety motion equipment that performs accordingly. At times, detection in mining may fail due to factors such as masking, which interferes with the camera’s viewing. Other problems facing detection in mining include false alarms caused by aspects of weather conditions such as wind, snow and the rains. Weather conditions may be uncontrollable, but modifications to harden the mast as well as stabilizing the mount of the camera could be of significant help. Effective motion detection in mining is also achievable via establishing the use of multiple video cameras within the mining scene. Multiple video cameras are capable of monitoring several areas simultaneously using diverse resolution, mask setting and zoom. In addition, the system can be implemented for big range of monitoring tasks. Detection in mining also covers detection of rock falls, which are a tragedy if not detected in advance. The system is set to record video frames and when the motion of rocks is detected, an audio alarm is triggered immediately. Algorithm, which monitors the intensity value of every pixel in the sight, enables detection to be accomplished and
when an ample variation is detected, the video frames that contain the motion are then recorded to the computer's hard drive, and thereafter the alarm is set in motion. Alternatively, through an Internet connection, the detective system can be configured to visualize the scene thereby dialing a designated telephone number in the event a trigger occurs. Video motion detection is vital as it detects the most minor changes within a mining surface; whether a rock fall or even wall hazardous cracking on the mines. Video cameras need only to be steady to be effective and free from causing false triggers. Recorded video images do not only aid in warning workers against dangerous working environs but they do also enable the mining investigators to reconstruct a rock fall as well as establish the unstable grounds of mining surface.
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DRILLING AND BLASTING Blasting has historically been a risky operation, but AEL Mining Services is intent on paving the way to zero harm and finding the 'missing link' to deliver optimal blasting solutions. This mammoth task requires the collective efforts of the industry to be truly successful, AEL Mining Services is calling on the industry to collaborate on efforts to improve workplace safety and risk exposure in the evolving mining environment.
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ero harm is possible, as AEL proved at Kumba Iron Ore's Sishen mine in early 2014, where a record blast of 311 mm holes with a total of 70 8446 t moved was achieved with an excellent safety record of zero injuries and zero incidents. Subsequently, the blasting section managed to set a new record for total tons blasted in a week (7.4 Mt) without an incident. At Sishen, AEL demonstrated its prime, load, tie and/or shoot (PLTS) service, which addresses the requirements of customers that face resource and construction constraints and therefore require a solution to these problems without the need to hire more or upskill existing members of staff. Safety is coupled with convenience due to the combination of AEL's technical expertise and adherence to legal compliance regulations. Leading the way in underground bulk systems “The underground mining method hasn't changed in 100 years,” says Tose. “To make inroads in safety and health, we have fundamentally changed our method. The emulsions we have developed for example can now be mixed where they are needed, even underground. This improves security and controls since the
chemicals only become active when mixed.” AEL's underground bulk system (UBS) comprises three components, emulsions which can be bagged or delivered to the working place through a pipe from surface, a sensitising agent and a pumping mechanism. While widely accepted as the industry standard for underground mining, it is continuously evolving within the walls of AEL's research and development department. New and improved emulsion formulations, pumping systems and value-add services targeted to this industry are constantly being realised as AEL continues in its efforts to improve its offering. Enhancing safety and reducing risk is one of the major drivers behind AEL Mining Services, and the company is constantly striving towards creating innovative technological advancements in the mining industry that better promote safety in the workplace and aim to reduce the exposure to risk. “This is about using the technology we have to improve on safety. There is a big push as an industry to make it safe and getting rid of the 'explosive' part makes it safer,” says Tose. “Here we have the solution – the missing link – now it is about getting it into the marketplace.” As an added benefit, UBS technology “is only explosive when mixed, so this prevents theft,” says Tose. Pilferage of explosives has been a challenge for many mines, but the UBS in-line
mixer and gassing solution is controlled on surface and the product only becomes an explosive once it is mixed through the lance at the stope face underground. Ever improving in Africa and beyond Improving the delivery of emulsions underground is an ongoing concern for AEL, as is “how we get even deeper,” says Tose, but the company's vision for ongoing improvement does not end with its products. AEL is not a product peddler but rather a value-adding service provider that strives to optimise its customers' mining operations. “For us, it is about being connected to a certain service, and we are interested in developing and matching solutions to problems. We want to get involved in the end solution rather than just the product itself,” says Tose. Another concern for AEL in terms of improving in Africa “is developing the mining industry while conserving national interest,” says Tose. “It is important to bring local communities on board. There is a lot of potential in Africa and the national interest is large, but it needs to be balanced.” Tose provides the new generation Bengalon nitrate plant in Indonesia as an example. “Our kits are mobile, so we can put plants in.
500 people from the areas surrounding the Pilanesberg mine.
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Vehicles & Edge Protection Transport accounts for a high percentage of accidents in quarries. It has been a priority for ASPASA for many years but until the industry addresses safe vehicle, safe workplace, competent driver and supervision it will not improve. None of the things set out below are complicated and there are some basic things that can be done straight away which will have a significant improvement in the figures. Look closely at you workplace, could this happen to you. Road vehicles – Your haul roads start at the or change your design. 10 degree slop is equivalent entrance to the quarry. Can a visitor find their to 17% which is a lot steeper than a 10% slope and way into the quarry and to a point such as car would be too steep for older dump trucks to stop on! park or weigh bridge if they are in a lorry Is there sufficient signage. Cars should not be allowed The failure to provide adequate edge protection is past the car park. Is reversing minimised. Many the cause of many of the vehicle incidents in loading points are too low for the vehicles that quarries. The recommended height is 1.5m or half are loaded there. This is not acceptable and the height of the largest wheel using the road or tip, arrangement must be made to ensure that whichever is the greater. As a rule of thumb if you vehicles can be loaded without reversing. can see over it is probably not high enough. The recommendation is the minimum that is required Have you considered whether the road vehicles and acts as an edge marker to warn the driver of the and site vehicles need to mix. Can the road vehicle. To stop the vehicle going over the edge vehicles be held in a holding bay until they are higher berms are required. These should be needed at the loading point. Can they be installed in areas where it is likely that a vehicle may separated from the site vehicles. What special go through the edge protection. precautions will be taken where they have to cross. Edge protection should be built on a good foundation. Sand pushed off the edge of the road Are the road surfaces suitable for road going will be too soft to work and give a false sense of vehicles. Tipping points for road vehicles shoul security. be level. These vehicles particularly articulated vehicles are prone to overturn if there is a cross Many of the tipping accidents occur when the rear grade, if the tractor unit is not straight with the wheel of the vehicle on the opposite side to the cab (on articulated vehicles) or where sticky driver goes over the edge and the vehicle falls off the loads are being transported. tip. To prevent this happening the following should always be followed:Although site vehicles are big and tough, they frequently overturn or are in a collision with one (1) Never reverse towards the tip edge unless another because they are being used in the adequate edge protection is provided. A minimum wrong conditions. It is essential that basic rules height of edge protection of 1.5m or half the wheel are observed. You should check your site rules diameter whichever is the larger must be provided. to ensure that they can be used safely. Always wear your safety belt; it would save 25% of all (2) Some vehicles have their cabs on the left and fatal accidents at quarries. some on the right; others are in the middle of the machine. Therefore always reverse at right angles Road widths – Roads need to be wide enough to to the edge protection allow vehicles to pass with ease, or if they are narrow one way working or traffic controls will be (3) Never reverse with the wheel diagonally needed such as traffic lights. For single track opposite to the driver approaching the edge roads they should be a minimum of two times protection first. Too many drivers have been killed the width of the largest vehicle. For two way doing this. roads they should be three and one half times the width of the largest vehicle using the road. (4) The edge protection must be provided on the The dimensions above are the minimum stable part of the tip – edges will fall away as the acceptable widths. ground stabilises Road gradients are often misunderstood. For (5) Visibility must be sufficient for the tipping rigid vehicles they should not exceed 1:10. This operation, with all round vision provided to the driver is not the same as 10 degrees. The following and adequate lighting if uses at night. In poor diagrams illustrate this. Brake testing results are visibility such as fog then tipping must be measured in % g and can be readily adapted to suspended. the use of % gradient above. For example a vehicle with 20% g brake efficiency would not Whether you are driving a road or site vehicle you stop on a slope of 1:5. Thus having designed must only tip on stable ground without a cross your roads you have to choose a vehicle that is gradient. You should not tip down hill as if the load suitable to work within your design parameters gets stuck it will tip the truck over. The best is to tip
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uphill on a slight gradient. Edge protection can be purpose built crash barriers or made from suitable materials such as scalpings. Boulders on their own are not suitable as edge protection but they can be used to delineate haul roads around flat areas of the quarry. Edge protection should be a minimum of 1.5m (5 feet) or the radius of the wheel i.e. half the diameter of the wheel or the axle height whichever is the larger. The front profile of the edge protection should be made so that vehicles will not drive up and over. Remember that edge protection can deteriorate due to weathering, so it must be properly maintained and inspected under the inspection and maintenance scheme. The purpose of edge protection is to warn the driver that the edge is there. It works by catching the vehicle or by overturning it back onto the road. To do this it has to be well constructed and sufficiently large to absorb the momentum of the machine. Part of the tip and excavation rules will have to determine the size of the edge protection you intend to use and where. Guidelines state that it should be 1.5m or the radius of the wheel whichever is the larger for most use. On ramps etc. you may need to put higher bunds in place.
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ASPASA - overview In instances where natural sand and gravel is unavailable, commercial aggregates are created by crushing large stones or by drilling and blasting rock formations and processing them into various sizes of rock and manufactured sand. This process is called "quarrying". Additional processes are required to produce different grades and types of aggregates and sand through drilling and blasting. These crushed stone products can be used for different purposes ranging from creating different grades of concrete, road surfaces or even for drainage purposes and to stabilise land. In the region of 130 quarries are represented by Aspasa. Building our country one stone at a time The Aggregate and Sand Producers Association of Southern Africa (ASPASA) is a voluntary producers association that helps to improve the quality of aggregates produced by its member companies for construction projects around the country. The role that Aspasa plays is critical considering that almost every structure made by man relies on aggregates for strength and stability. In fact, construction aggregates are the primary ingredients of all concrete structures and foundations (80% of concrete is aggregate), as well as being the single most important ingredient used to build our roads (94% of a road is aggregate). “Aggregates and sands used in construction projects are naturally occurring minerals that are mined by a specialised sector of the mining industry in South Africa mainly from quarries. Government strictly regulates sand and aggregate quarries due to the importance of obtaining a reliable supply of quality materials. It also aims to ensure that the minerals and materials are removed in a manner that is sustainable and protects the rights of workers, as well as the environment and surrounding communities.
Responsible association
relationship with the country's training authorities, as well as hosting regular workshops and seminars,” Nico says.
Working together He explains that quarries represented by Aspasa work closely with the Government and the Chamber of Mines and are able to give input on a wide spectrum of legislation that affects the industry, including input on critical issues surrounding the environment, as well as health and safety matters. These important issues are represented through expert committees with senior and knowledgeable specialists serving to give informed input on all matters. Through these committees programs are may also be developed to assist the industry to meet development objectives and improve the overall standards on member mines. A specialist technical committee also represents the industry on matters that can influence the industry. It works with other industry bodies to ensure that specifications for construction work are up to standard and cost effective. Other work carried out by the association includes assistance with human resources, remuneration surveys, workshops on Aids and labour law, employee product assistance (medical aids, pension etc). The association also actively promotes the industry as well as the importance of using Aspasa accredited companies.
Adopting change “In addition to this Aspasa supports the adoption of a proactive strategy to foster change and to encourage black economic empowerment and transformation in a sustainable and economically sensible manner. For this reason we subscribes to the aims of the broad-based black-economic empowerment charter for the mining industry. In particular, the pillars of transformation related to: · · · · · ·
Human resources development Employment equity Encouraging greater community participation and development Promoting greater procurement from HDSA companies Encouraging greater HDSA ownership and Participation and facilitating beneficiation
“These are not only supported, but we believe will contribute to sustainable development in South Africa,” Nico concludes.
“As a private sector association representing producers in the industry, we uphold these aims. In addition we strive to create an economically viable industry with good interaction between all parties involved, from the industry, as well as the relevant government departments and other stake holders. “Our focus remains largely on creating an environment that is fair and equitable, gives our members space to manoeuvre and to make a good living. On the other hand we expect members to comply with all relevant legislation, as well uphold the strictest standards in quality, health, safety and environmental issues. Annual audits are in place to assist members to achieve set requirements and also to ensure that they comply with the relevant legislation “We also encourage skills development and nurturing of expertise though our close working
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plit roller bearings are bearings that have been split horizontally through the bore, and can therefore be removed or installed without having to be slid over a shaft end. Split bearings can be changed, or installed without auxiliary equipment being removed from the shaft ends. Typical positions for split roller bearings are on critical equipment, trapped locations between drives and driven equipment, where access is difficult or where sealing or contamination issues affect conventional bearing arraignments. Typical applications for split bearings are fans, conveyor drives, continuous casters in the steel industry, and mill pinions to name a few, but applications are really limited to your imagination. Split roller bearings are available in three load capacity series, namely Light, Medium and Heavy series. Therefore a bearing can be selected to best suit the application depending on the load and speed of the application. As split roller bearings have machined brass cages they tend to exceed the speed capacities of most spherical roller bearings. Split bearings are not a new concept and have been used successfully in industry for over a 100 years. This proven concept is available in a variety of mounting, including Flanges, Take up units, Hangers for screw conveyor center bearings, and Plummer block type units. With SRB's development of the SN/SD interchange mounting arraignment with matching bolt holes and center heights to Plummer blocks, the growth in the split bearing market has been exponential. So much so, that forward thinking Engineers are specifying SRB's at design stage due to the ease and simplicity of replacing components whilst still coupled to the drives. The sealing arrangement of split roller bearings is also capable of withstanding the harshest and most aggressive environments. Over the years many bearing companies have manufactured split bearings, but have stopped production as the split bearing market is a niche market, so it is not viable to make split bearings in a factory that is set up to mass produce bearings. SRB bearings are almost handmade, at the Revolvo factory in England where the product was developed. The SRB product range has a number of advantages over other split bearings in that all SRB bearings have notably higher capacities, stronger cast iron and a
superior machined brass cage as standard on all their bearings. OE Bearings are the sole Sub-Saharen agents for SRB Split roller bearings. OE Bearings is unique in that they are the only bearing company on the African continent that deal exclusively in split bearings thus making them The only Specialist split Bearing company. The bearing assembly is split to the shaft and can thus be changed in an hour or less, as the working loads are halved and halved again, so the man power required to change the bearing is also reduced. Where as a solid bearing in a trapped location could take any time between 8 to 24 hours to replace and in specialized cases up to 3 weeks. With down time costs and labour costs running into hundreds of thousands of Rands. “In such cases, the benefits of using a split bearing are obvious” The sealing arraignment of SRB's is vastly superior to that of a conventional external bearing, as the split bearing unit has an external misalignment feature so the shaft and seal remain concentric and the seal tolerance is maintained. Of conventional externally mounted bearings, less than 70% of bearings achieve their design life, primarily due to lubrication failure as a result of contamination. Due to SRB's sealing arrangement and the fact that new lubricant is applied to the rollers and working surfaces of the bearing, our customers are reporting that SRB's exceed the previous bearing life by more than 60%. As the quantities are so small, the bearings are almost handmade, they are more expensive than mass produced solid bearings. This price difference is often negated by the labour saving, and if downtime and loss of production is considered, then the cost of the split bearing unit becomes a mute point. OE Bearings not only supply Split bearings but are also actively involved from design, to commissioning of bearings sold. To this extent, we identify and experience issues our customers face from time to time. Following our onsite experience, OE Bearings in conjunction with the Revolvo factory ,developed the SN SD interchange, this allowed for a split bearing unit to be fitted in place of a conventional Plummer block without structural modifications having to done, as was the case before the birth of SRB.
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LOULO-GOUNKOTO SUCCESS DRIVES SUSTAINABLE DELIVERY OF LOCAL COMMUNITY BENEFITS The Loulo-Gounkoto gold mining complex, the largest of its kind in Mali and one of the largest in Africa, continues to make strong headway in its drive to increase production and contain costs, said Randgold Resources' chief executive Mark Bristow. Bristow said that the complex's importance to the Malian economy was demonstrated by the fact that it currently accounts for some 8% of the country's GDP. In addition to the substantial contribution it makes to the Malian treasury in the form of dividends, taxes and royalties, LouloGounkoto's continuing success has also enabled it to provide a wide range of life-changing benefits to local communities. This, he said, was in line with Randgold's commitment to share the value it created with all its stakeholders, including the people of its host countries. One of the major achievements of this approach was the significant contribution Randgold was making to national skills growth in Mali through scholarship programmes, hands-on training and career development. As a direct result of this effort, LouloGounkoto is managed and operated by an almost entirely Malian team, with the country's nationals accounting for 94% of the total workforce. In addition, the complex has set up community-led commissions to direct each of its strategic community investment sectors, including potable water provision, education, healthcare and food security. Investment projects are run by the community, with guidance from Loulo-Gounkoto's management. Another initiative is the development of local agribusinesses. The relevant community development committees are being converted into cooperatives, which during the course of this month will be securing agricultural land selected by the communities and tested by Mali's National Agricultural Institute. Construction of an agricultural training centre will also start this month and a number of pilot
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projects, which will serve as training units, have been identified. To boost the local economy generally, the complex will fund a microfinance provider to help finance small business initiatives, particularly those started by the women in the community. “As the two key stakeholders in this complex, the government of Mali and the management of Loulo-Gounkoto have a joint responsibility to ensure that it continues to generate substantial benefits for its communities and the country, not just for today but for future generations,” Bristow said. “One of the issues we still have to address together is the challenge of illegal mining, which impacts on LouloGounkoto's capacity to deliver these benefits and, even worse, is threatening the integrity of Mali's vitally important national assets, damaging the environment and exploiting sectors of the community.” In the second quarter to June 2014, the Loulo-Gounkoto complex again lived up to its status as Randgold's flagship operation by posting a 3% increase in production to 174 052 ounces – its third successive record breaking quarter. In addition to a strong operational performance, the Loulo team also completed the Yalea pastefill plant, which was successfully commissioned in July. Commissioning of the Gara pastefill plant is scheduled for September. Loulo-Gounkoto general manager Chiaka Berthe says the significance of this advance is that the paste backfill will enable miners to extract virtually 100% of the high grade zones at Yalea and Gara. It will also reduce the need to develop and mine secondary stopes and facilitate the optimisation of the ventilation systems. The interim CAF backfill operation is now being phased out but served as a useful training ground for its operators who are being transferred to the pastefill plants. Another major milestone achieved
during the quarter was the progress made with the installation of two new medium speed generators, designed to cater for the complex's growing power needs while keeping a reign on energy costs, which are due for commissioning in the second half of this year. Power is, by a wide margin, the largest component of any mine's cost structure and since 2010 Loulo-Gounkoto has been switching to medium speed generators capable of running on the less expensive heavy fuel oil, thus driving down the kilowatt/hour cost of its energy consumption. The next stage is to continue working with the Malian authorities and other regional governments on the West African regional power project which, if implemented, will not only reduce Loulo-Gounkoto's energy costs further but will unlock many mining opportunities in the region which are currently not viable. Samba Toure, Randgold GM operations for West Africa, said the gratifying results achieved to date by the LouloGounkoto team were a tribute to years of hard work. “But a winning team such as this always see more achievement opportunities, and they're already looking at further performance enhancements,” he said.
GRP PIPES - THE RESPONSIBLE CHOICE FOR MINING INDUSTRY APPLICATIONS
JOHANNESBURG, OCTOBER 2014 - Labelled the 'pipe of the future', corrosion-resistant, glass-reinforced plastic (GRP) pipelines can save mining companies millions on reoccurring pipeline breakdowns due to corrosion. Fiberglass-reinforced plastic pipes are now considered exceptionally advantageous in the mining industry where highly-resilient materials are required to withstand corrosive chemical used and harsh environmental conditions experienced in the mining process and in particular metals processing plants. Roger Rusch, CEO at IWC, experts in GRP manufacturing and installations in South Africa and Africa, says “GRP pipes are well-priced, do not require maintenance and are designed to have a lifespan of around 50 years, which is a huge saving on the life cycle cost over a 50-year period, especially in the mining industry where conditions are harsh.” In response to the growing demand for fibreglass equipment and piping, in 2012, Industrial Water Cooling, IWC, officially launched a glass-reinforced plastic (GRP) manufacturing facility in Isando, Ekurhuleni, which is one of only two GRP plants of this kind in South Africa. Before IWC launched its GRP facility, the biggest local supplier of industrial fibreglass was based in KwaZulu-Natal. “Our facility offers a range of services and products including on-site GRP piping repair work as well as the manufacturing and design of corrosion resistant linings and fittings for pipeline systems.” says Rusch. IWC's GRP manufacturing facility undertakes the design, manufacture and installation of GRP piping and fittings from 25mm up to 2500mm in diameter Polypropylene; PVC and HDPE vessels and piping; and GRP corrosion resistant linings.
Fiberglass-reinforced plastic is constructed by weaving together individual strands of fine glass fibre to form a flexible fabric, which is then placed in a mould and combined with resin. This process is then repeated in order to create many layers of the fibre glass and resin, which then becomes a high performance material of exceptional strength and versatility. The resin most commonly used in GRP is unsaturated polyesters dissolved in styrene. Polyesters can be tailor-made to specific industry requirements. Owing to its strength, durability and non-corrosive properties, GRP pipe systems have a longer life expectancy when compared to a variety of construction materials, making it massively economical over the long run. Furthermore, glass reinforced plastic pipes are considerably less expensive than those manufactured from materials such as stainless steel or more exotic materials that are required in the metallurgical processing industry Due to its unique physical properties, glass-reinforced plastic can be easily moulded and manufactured to meet almost any industry specifications. With GRP, there are few constraints on size, shape, colour or finish. Pound for pound, GRP is stronger than steel and sheet metals, has a high resistance to environmental extremes, and is resistant to ultra violet light, extreme temperatures, salt air, and a variety of chemicals including most acids. The advantages are of GRP are unmatched and with years of experience and their own plant, IWC consistently undertakes custom GRP piping and fitting solutions, from the simplest, to the most challenging applications in the African mining industry. About IWC Industrial Water Cooling (Pty) Ltd (IWC) are a specialist water cooling company, with specific strength and focus on evaporative cooling systems and cooling towers in particular.
IWC was founded in 1986 and specialises in evaporative water cooling for numerous applications. Some industries in which we are involved are: Power Generation Mining Petrochemical Sugar Steel & Aluminium Food & Beverages Air-conditioning, Refrigeration and many other applications For many years IWC has been a member of the CTI, Cooling Technology Institute, based in the USA. This association has as its member's consultants, designers, constructors as well as end users of cooling towers. With years of expertise and practical knowledge, IWC offers bespoke PHE maintenance solution at cost-effective and competitive pricing. Due to IWC's extensive experience in the refurbishment of cooling towers it has undertaken in excess of 80% of the Natural Draught refurbishment work conducted in South Africa. IWC has completed the on-line refurbishment of a Natural Draught Cooling Tower in Australia and also in South Africa & Zimbabwe.
MEDICAL, RESCUE AND MANAGEMENT
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Emergency medical and rescue services in remote areas
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Occupational health services
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Staffing clinics with doctors,nurses and/or paramedics
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Ambulance operations
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Ebola isolation camps
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Remote site clinic management
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Ebola protective equipment
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Medical equipment and consumables
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Disaster trailers
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Rescue equipment
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First aid kits
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Ebola PPE
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Fire extinguishers
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Ambulances and equipment
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TRAINING •
First aid training
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Basic fire awareness training
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Wilderness first-aid
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Fleet driver ssafety training
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Paediatric first-aid
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EZEHUT PRODUCTS 227 Vonkprop street Samcorpark PO BOX 325 Silverton 0127
WHERE POSSIBLE ALL MATERIALS USED ARE SABS MARK BEARING Panels used by Ezehut consist of high-impact resistant, exterior grade Masonite weatherboard, bolted together with a reinforced galvinised steel work frame. All materials are extremely durable. ECONOMICAL Structures can easily be erected by unskilled labour—all holes are pre-drilled and erection instructions accompany each structure purchased. Also easily dismantled and transported. DURABILITY UNSURPASSED Backed-up by more than 30 years experience in the prefabricated industry. WINDOWS Windows are supplied unglazed. Burglar guards are an optional extra. FLOORS No flooring materials are supplied. Floors can be constructed from concrete, bricks, pavers or any suitable material. * ALL SIZES ARE APPROXIMATE. STRUCTURES CAN ALSO BE MANUFACTURED TO CLIENT’S SPECIFICATIONS.
Phone: +27 12 803 7433 Fax: +27 12 803 6211 Sales Consultant: victormasemola@telkomsa.net E-mail: sales@ezehut.co.za website: www.ezhut.co.za
MM&G Mining and Engineering Services MM&G Mining & Engineering Services walked away as the overall winner at the 2012 Steel Awards. The giant chimney flues and platform steelwork project the company completed at the Medupi Power Station in Lephalale, Limpopo, also won the Mining and Industrial category prize. The annual Steel Awards, presented simultaneously in Johannesburg, Durban and Cape Town on 6 September, serve to recognise and applaud exceptional achievements within the steel industry and aim to recognise and promote excellence and entrepreneurial development in the industry, principally in South Africa, by profiling innovative thinking and successes from the industry, both locally and internationally. Boksburg based MM&G competed with entries from local as well as international individuals and companies involved in the production, conversion, distribution, use of recommendation of carbon and stainless steel. MM&G received the order for a fast track project on the Medupi Power Station in December 2009, said CEO Dawie Vos. “The project entailed the supply and fabrication of flue gas ducting for two 220 meter high chimneys, each containing three flues. This was the largest project MM&G had ever attempted and completed successfully in its 34 year history. The timely construction and handover of 120 steel units, consisting of 18 stainless steel units (316L material), 102 mild steel units (S355JR material) and the remainder of 24 mild steel lobsters (S355JR material) are evidence that MM&G can compete with the best,” said a proud Vos. The judges stated that in spite of strong competition from
the other four category winners, the fabrication of the complex platforms and flue cans for the world-class Medupi chimneys truly showed the “wow” factor that separates the 2012 Steel Awards winner from the rest. The total weight of all the units was approximately 2400 tonnes, of which the stainless steel component accounted for 330 tonnes and the mild steel components, including lobster, accounted for 2070 tonnes. Jurie Human, project director, said there seemed to be a perception that MM&G would be unable to complete the project within the agreed upon time frame. “We proved the nay-sayers wrong. We fabricated our own workshop in record time on the Medupi site during January and March 2010, and the project started in all earnest in May 2010 with the first items of diameter studies, and the first trial assembly done in our Boksburg Workshop,” said Human. All the components for the first three flue gas ducts, for the South Chimney, were due for completion by 20 March 2011, a date to which MM&G kept as a result of excellent planning and execution of the project, said Vos. The completion date for the second delivery of flue gas ducts, for the North Chimney, had been set for 20 October 2011, and was completed early on 9 September 2011. The total design of the interior stiffening and fabrication methodology for the flue gas ducts was done by MM&G, and was monitored by a computer programme specifically written and developed for this project in-house. Just in time delivery of value added raw material from the Aveng Trident Steel group contributed to the successful delivery of the entire project.
“The strategy was developed around a definite goal with handpicked individuals to deliver the project. The fact that the same project team worked on the project from commencement to completion, played a considerable role in our success. The same key people who designed and planned the project, also brought it to a successful conclusion, and are still with the company today,” said Vos. MM&G did face some safety challenges on the South Chimney with two lost time injuries during November 2010. They learned from the mistakes made, and after that MM&G maintained an excellent safety record throughout the project. The fabrication and erection of the flue gas ducts was completed without fatalities to the workforce, consisting of an average of 80 workers, increasing to a work crew of 107 at peak production times. MM&G is particularly proud of the fact that the project was completed with local content and workforce. “There were challenges to overcome, some delays due to labour strikes and xenophobic unrest, as well as the harsh weather circumstances in which the project had to be completed. Our workforce endured and persevered in temperatures that had the mercury rising to up to 54°C. Despite these potential stumbling blocks MM&G managed to complete the work within the agreed upon time frame,” said Vos. MM&G maintained an excellent quality record: The company experienced no quality rejections throughout the project, and to date there have been no rejections due to any defects. This success can be attributed to MM&G's 100% ISO compliant Quality system, said Vos.
MM&G continually strives to improve its position as a premier steel fabricator and Construction Group
Dawie Vos Email: dvos@mmg.co.za
Jurie Human Email: jurie@mmg.co.za
Specializing in Structural Steel, supplying and servicing the Construction and mining industries. MM&G are specialists in:
106, Cnr Bain & West Street Boksburg East Tel: 011-914-4740 Fax: 011-914-4673 Email: info@mmg.co.za Website: www.mmandg.co.za
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Shaft & Station Steelwork and Shuttering Gantries & Pipe rack Fabrication Plate girders design and fabrication Pipe & Tower Structures Screw Pile foundation Overland conveyors Structural Steel Fabrication
PO Box 8908 Cinda Park 1463
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High Performance Excavation Equipment
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suction tube is toothed at its end in order to cut the earth during excavation process. When the excavator is used to suck out debris, the earth is first loosened with a compressed air lance or a water jet and this type of excavation where a water jet is applied is referred to as hydro excavation or vacuum excavation. Suction excavator is significant in that, it does not expose the buried utilities in the underground to damage while the equipment is used for utility finding process.
xcavators are heavy machines that are used for digging and trenching activities. Excavator equipment has served great purpose in mining industries whereby mining activities are done easily and effectively. In view of the suction excavator, a proper understanding of excavation equipment operating in underground can be achieved. A suction excavator is as well known as vacuum excavator, vacuum tanker or vacuum lorry. Vacuum excavator flow chart It is a construction vehicle whose purpose is to The excavation process by a vacuum excavator remove debris from the underground through a wide is not complex. The Vacuum Excavator suction pipe whose diameter is approximately thirty generates a high volume flow of air by the help centimeters. of its triple air fans. The air is then flown through the intake nozzle and hose into a Suction excavator in operation series of chambers and the main material By the help of suction power, the excavator storage before it is passed through the mesh operates at a hundred meters per second. The
filter system and next into the atmosphere. The ground material under excavation is deposited to the main storage tank when the operator directs the machine's intake nozzle at the excavation ground and the air flow vacuums the ground material into the vacuum excavator. Soil particles are collected in tanks where dust particles are caught in the micro mesh filter system before the air finally passes from the machine. When the ground conditions become a challenge, the trained operator uses an air lance or other air tools, which are usually connected to the vacuum excavator. The ground is loosened through this tool, allowing the air flow to catch the material releasing it into the vacuum excavator. The use of vacuum excavator in excavation field as a new approach is not necessarily meant to replace the traditional or hand dig methods, which are still applicable in excavation process.
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ReMaCon offers the YFEL – a modular concrete wall for the separation of dry bulk minerals and TW1 - retaining blocks for mine tip wall construction. ReMaCon Products have been
accommodate changing storage
extremely difficult to climb over. In
manufacturing precast concrete
requirements. In mining there is a
addition, services such as cabling and
retaining blocks since 2005. The YFEL
requirement for different grades to be
water pipes can be placed through the
system has recently been launched. It
separated. The YFEL system is a
spayed void.
is an innovative modular product that
convenient, flexible and new approach
provides a flexible alternative to the
to the traditional methods currently
Conduits can be cast into the YFEL to
conventional ways of separating stored
employed. The YFEL concept has been
but cables through to fit lights or
dry bulk materials.
successfully applied and proven
cameras on the YFEL for additional
abroad. It will also assist companies
security.
The YFEL system – check the website for the product in action yfel.co.za/
with ISO compliance issues in terms of material separation.
The YFEL product is manufactured to order in heights ranging from 1,2 m to
The YFEL derives its name from the
4 m. The product can withstand
inverted “Y” shape with its
abrasive construction machinery
resemblance to the famous Eiffel
handling due to the 50MPa concrete
Tower in Paris. It is designed to
strength and steel reinforced design.
provide easily erectable temporary or permanent walls as dividers in
The YFEL can be bolted into the floors
warehouses and other areas where any
of warehouses and other storage areas
dry bulk materials are stored and
for extra stability. ReMaCon can
separated.
supply attachments for moving by forklifts onto and off trucks and for
Unlike the traditional permanent
positioning on site are available.
concrete walls that are built for separation, the YFEL is easily moved
ReMaCon offers the “ANTI-
about allowing the freestanding walls
CLIMBTM” security feature on the top
to be quickly dismantled and moved to
of the YFEL unit making the unit
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Feature CONDITION MONITORING LEADERS EXPAND NETWORK IN AFRICA WearCheck - Africa’s leading condition monitoring company serves the earthmoving, industrial, transport, shipping, aircraft and electrical industries through the scientific analysis of used oil from mechanical and electrical systems. Additional services include the analysis of fuels, transformer oils, coolants, greases and filters. The introduction of a highly capable Reliability Solutions division has transformed WearCheck into a ‘one-stop shop’ for condition monitoring, offering vibration monitoring, laser alignment, thermal imaging and balancing. An expansive network includes ten WearCheck laboratories spanning the continent and beyond, including Gauteng, KwaZulu-Natal, Mpumalanga Province, and international laboratories in India, Dubai, Ghana, Mozambique and Zambia - at Lumwana mine and Kitwe - with a presence in Cape Town, Rustenburg, Steelpoort, Port Elizabeth, Zimbabwe and Namibia. Managing director Neil Robinson explains, ‘The concept of analysing oil samples from a machine or component is similar to that of taking a blood sample from a person - the results determine the health status of the unit. WearCheck’s highly-skilled diagnostic team then analyses the results and recommends how to rectify any abnormal findings.’ Robinson is committed to ongoing investment in new technology to ensure that all laboratory equipment is state-of-the-art and rivals, often surpassing, its local and international counterparts. All laboratories are largely automated and integrated with the latest information technology. Research and development plays a major part in WearCheck’s commitment to continual improvement.
WearCheck’s reliability solutions manager Philip Schutte is dedicated to the optimisation of plant performance management. ‘To ensure that plant operates at peak performance in order to achieve maximum efficiency and, ultimately, boost the bottom line, we now offer a range of monitoring techniques, such as the testing and control of the efficiency of combustion, heat transfer and milling,’ he said. WearCheck also offers several other solutions to keep plant performance operating at its peak, including: The Station Thermal Efficiency Program (STEP), Coal Accounting and Plant Performance Monitoring Services. Plant Performance Monitoring of Boiler, Turbine and Auxiliary Plant. Routine testing and verification of raw data from plant used in the STEP system or similar programs to produce thermal performance results. Investigations and report with recommendations on the plant failures or incidents. Advice on the plant performance tests, including the load lines, clean air curves, plant inspections, air flow test, air heater leakage tests, O2 verification tests, temperature traverse tests, gas velocity tests, condenser tests, dew point test, pulverised fuel sampling tests, generator H2 leak test, HP & LP heater performance tests and any other performance and testing tests required for the plant optimisation. Assistance with the following during outages: air heater shoe gaps and seals settings, pulverized fuel burner settings, mills settings, draught plant settings, zeroing of coal conveyor mass meters and any other settings that may be required during the plant outages.
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Weekly plant walk-downs and liaison with the operating department for any deviations that are visible on the plant for corrective action to be taken. The activities are performed on the whole station, including turbine, boiler, mills and outside plant. Backed by certification from Paris-based Bureau Veritas and Honeywell, WearCheck is the only oil analysis company in Africa with ISO 9001 quality certification and ISO 14001 certification for its environmental management programme, and ISO 17025 accreditation for its laboratory-centric quality management programme. WearCheck has been awarded preferred supplier status by several Original Equipment Manufacturers (OEMs); notably Bell,Liebherr, Volvo Construction Equipment and,along with WearCheck’s global partners, is the laboratory of choice for a number of lubricantsuppliers. WearCheck also has a partnership with ABB Limited, Zurich - a global leader in power and automation technologies. These partnerships are in line with worldwide trends in outsourcing specialist services. WearCheck’s operational areas are managed ethically and independently to ensure products and services conducted comply with the company’s strict international standards. WEARCHECK’S CONTACT DETAILS: Email: support@wearcheck.co.za Web: www.wearcheck.co.za Tel: Durban (South Africa) (head office) Tel: +27 (0) 31 700 5460
Captions: 1. Condition
monitoring specialists WearCheck process in excess of 600 000 oil analysis samples each year in ten laboratories. Here, despatch clerk Michelle Alexander sorts oil samples.
2. The most recently-opened WearCheck laboratory is in Tete, Mozambique – their first in East Africa. Equipped with the latest high-tech instruments, the lab offers fast sample turnaround time and highly accurate oil analysis results. 3. WearCheck’s managing director, Neil Robinson, believes that a combination of ongoing investment in the latest technology, unwavering service excellence and a strong focus on ethical management, ensures that his company remains at the helm of the proactive condition monitoring industry. 4. WearCheck’s reliability solutions manager Philip Schutte and his team focus on optimising plant performance management. They have developed a comprehensive suite of tests to monitor potential problems using techniques such as vibration monitoring, thermal imaging and laser alignment. Released on behalf of WearCheck by Sharon Fay Public Relations Media queries:Sharon 082 8230539 or sharon@sharonfaypr.co.za
Kipoi Mine in DRC
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ipoi mine is a joint venture located in the province of Katanga in DRC whose main mining product is copper. Kipoi mine in DRC is a project owned by Tiger Resources, Gé camines company. Just like any other project of a given company, Kipoi mine in DRC has had challenges and achievements through goals and plans set upon it. These are occurrences that have taken place in the recent years bearing in mind that Kipoi mine in DRC is a project whose production objectives were set to be fulfilled in the last few years. For instance, a target had been set that the mine should reach a capacity of 100, 000 tons of copper metal per year and by the year 2011; the mine had managed to produce at least capacity of 130,000 metric tons. Kipoi mine project enabled its respective company to make a record of quarterly production in DRC. The Tiger company produced over twelve thousands tons of copper from its heavy media separation plant in the September quarter, which was an indication that in percentage of thirty five, it was higher than the plant's nameplate capacity as well as than the previous quarterly production record with percentage of nine. As a result, the project became good enough to be recognized as a world class project with an outstanding team of the company. In the year 2013, Kipoi Mine Company in DRC could produce above thirty two thousand tons of copper in concentrate which was an achievement that gave great impression that it has ability to operate
consistently above the nameplate capacity. It is in the same year that the company managed to increase the copper stockpiles to 4.7 million tons, which were planned to be used as feed to stage two plant known as solvent-extraction electro winning (SX-EW) in the recently passed year 2014 and hopefully in the current year 2015. On the other hand, government policy was speculated to be a limitation to the Kipoi mine project, when the DRC government decision pronounced banning of copper and cobalt exports. In addition, the country pressed that the companies should process and refine the metals within the country's borders. On the contrary, there was a great domestic demand for the Tiger's product which was especially marked by smelters within DRC. Thus, this turned out to be an advantage to the Kipoi mine project as more than eighty percent concentrate of its product was sold to the smelters within the same period. Also in support of the same government, the remnants of the Kipoi mine project products were exported to Zambia. In conclusion, it is clear that the Kipoi mine project in DRC has gone through phases especially in the year 2013, which have reflected a promising future for Tiger Company. Needless to mention that the DRC government and the heavy media separation operations have as well supported Tiger's company operations, which will enable the company to produce high-value added copper cathode products.
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ASSA ABLOY Entrance Systems, the world’s most comprehensive supplier of entrance automation solutions, proudly introduces the Albany RR1000, a tough, high-speed rubber door refined with a sophisticated new design.
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his attractive yet rugged highperformance door packs strength and power into a low-clearance header with a sleek finish, thin low-profile side frames and a versatile rubber door curtain available in a range of colors. Independent windperformance tests have shown that the Albany RR1000 can safeguard people and goods, resistant up against strong gusts of wind and extreme weather conditions in exterior applications, and withstanding air pressure in interior applications. Even hurricanelevel winds should not derail the Albany RR1000, which can tolerate 130mph windloads. The rubber door panel is designed to remain firmly in the side-frame guides without lifting upwards, a common problem when traditional bottom seals meet intense wind and air pressure. This strength and reliability is backed by a lifetime warranty on our thick, high tensile strength rubber door panel. This resilient performance is matched with an aesthetically appealing design, making the Albany RR1000 an excellent choice for buildings aiming for architectural elegance and style. Be it a parking garage on a state-of-the-art office building, a busy 30
manufacturing facility or a mining operation set in harsh environmental conditions, the Albany RR1000 is suited to operate exceptionally and look good. When fast-paced operations are busy, accidents are inevitable. The Albany RR1000 will break away easily, and can be reset simply and quickly with the push of a button. This self-repairing, break-away function rounds out a full host of features, including impressively high opening-speeds of up to 60” per second and superior safety systems to protect people and equipment. “We’re proud to offer this innovative product that will change the face of the highspeed door industry,” says Juan Vargues, President and CEO of ASSA ABLOY Entrance Systems. “With the high wind resistance and the refined design, the Albany RR1000 is unprecedented in today’s market.” For more product information regarding Albany mining and industrial doors, please contact: Maxiflex Doors Systems, info@maxiflex.co.za, +27 11 3921709
RKA CONSULTING PILNESBERG PLATINUM PROJECT
We are the Leading Supplier of Technical Support , Training and Product Sales of GE-IP Software in South Africa .
Platinum Mines Ltd
Specializing in IFIX , FIX32 , FIX DMACS , Proficy Historian , Proficy Portal from GE Intelligent Platforms ( Ex GE Fanuc , Ex Intellution ) Postal Address PO Box 12130 Vorna Valley 1686 South Africa To contact us: Phone: 083 456 4165 or 011 8055744 Fax: 0865030094 E-mail: ziggy@rkaconsulting.co.za RKA Consulting cc Midrand South Africa RKA Consulting cc
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