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May - June 2018, Volume 13 No.3

Boosting aging power plants As the continent is engrossed in the euphoria of renewable power generation, it would be remiss for power utilities to neglect the urgency of retrofitting old power plants.

Inside

● Locomotive leasing: Gaining traction ● Life-saving messages delivered instantly through metal

Front Cover:

Contents May - June 2018, Volume 13 No.3

Editor’s word

inside this issue... Conveyor gas detection

6

Timely detection for effective mitigation

Boosting aging power plants

Modular Steel Bolted Tanks EDITOR Jimmy Swira GRAPHIC/WEB DESIGN Augustine Ombwa austin@arobia.co.ke Writers: Nyiko Mahundla, Matimu Mahundla COUNTRY LIAISON Thuthukile Mhlanga Thuli Nkosi ADVERTISING EXECUTIVES South Africa: Winnie Sentabire, Thunile Nkosi, Rachel Molapo, Angeline Ntobeng, Nigeria: Seni Bello

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for Mining Requirements

Side channel blowers

16

Blowers made for most demanding tasks

LV Switchgears 21 JB Switchgear appointed as Blokset partner in South Africa

Robotic cathode stripping

27

Robotic reliability

Cathode edge strips

33

Extending cathode uptime

Power plant retrofitting

38

Boosting aging power plants

Cable management

48

Reliable cable experience Published by College Publishers a subsidiary of Group Africa Publishing Ltd African Mining Brief is published six times a year and is circulated to members of relevant associations, governmental bodies and other personnel in the mining industry as well as suppliers of equipment, materials and services in Africa, the Middle and Far East. The editor welcomes articles and photographs for consideration. Material may not be reproduced without prior permission from the publisher. The publisher does not accept responsibility for the accuracy or authenticity of advertisements or contributions contained in the journal. Views expressed by contributors are not necessarily those of the publisher.

Mobile OTR tyre processing solution for mines

52

Turning tyre trash into treasure lawfully

Condenser tube cleaning

56

Cleaner condensers for peak plant performance

Hybrid power generation

60

Determining the most reliable and lowest cost power solution

© All rights reserved.

The editor accepts letters and manuscripts for publication from readers all over the world. Include your name and address as a sign of good faith although you may request your name to be withheld from publication. We reserve the right to edit any material submitted . Send your letters to: info@collegepublishers.co.za

Go back to basics!

O

ne of the most ignored topics in discussions on commercial-scale power generation in Africa is little or lack of maintenance of aging power plants - ironically, some of which were built by colonial powers over 50 years ago. And as a result of sheer negligence of the responsible quasi-government’s entities, frequent downtime affects the performance of power plants in countries, which is costing industries hundreds of millions in loss of revenue due to low productivity. Preposterously, unable to carry out basic maintenance of existing power plants, some countries are embarking on Greenfield power generation projects, which require billions in capital and expertise, not readily available in most African countries, to implement. Questioning the sanity of this move, some commentators contend that retrofitting existing power plants would increase capacity and cost significantly less than a new project, and a service would be readily available to end-users in no time. Indeed, new projects take years to come on stream - from feasibility stage, conceptualisation to commissioning, while the economy stagnates due to lack of power. Isn’t time we go back to basics of maintenance and fix problems with current existing power plant?

Jimmy Swira Regional Offices South Africa Office College Publishers Ltd 1st Floor, No.267 Oak Street, Oakfields, Randburg Tel: +27 11 781 4253 / Fax: +27 11 781 4287 E-mail: info@ collegepublishers.co.za

Kenya Office Northwest Ventures Ltd P.O. Box 16414 Nairobi 00100, Kenya Tel: +254 20 2679809, 2679808, 2091305 Email: kenya@ groupafricapublishing.com

Zambia Office Dayflex Limited, 4th. Floor Tazara House Dedan Kimathi Road, Lusaka, Zambia. Tel: +260 211 230 529 / +260 977 756 663 Email: makukasue@mail. com E-mail: dayflex06gmail. com

Nigeria Office B23/24, Aishetu Emoewa Plaza, 196, Iju Water Works Road, Ifako Ijaye Lga,Agege, Lagos. Tel: 234-1-7347860 Email: nigeria@ groupafricapublishing.com

Uganda Office Smg Uganda Limited Kamukamu Plaza, Entebbe Road, Kampala-Uganda, Tel: +256 774 079 804, uganda@ groupafricapublishing.com

Ghana Office Image Consortium Limited 1st Floor, The Trust Bank Building, Tesano Tel: 233(0) 302 232 728 Fax: 233 (0) 024 882 8286 Email: ghana@ groupafricapublishing.com


NEWS

Angola

Angola

Sierra Leone

46 carat pink diamond recovered in Angola

Laúca set to become Angola's largest Hydropower Plant

De Beers to launch pilot project for artisanal miners

Angola focused, Australian diamond mining company, Lucapa Diamond Company Limited and its partners, Empresa Nacional de Diamantes E.P. and Rosas & Petalas, have announced the recovery of a large gem-quality 46 carat pink diamond from the Lulo Diamond Project in Angola, according to a statement issued by the Steven Wetherall, the company’s managing director. “The 46 carat pink is the largest gem-quality coloured diamond recovered to date from the Lulo mining operations, eclipsing the 43 carat yellow gem recovered in January 2018 and the 39 carat pink recovered in September 2016,” commented Wetherall. Significantly, the 46 carat pink, along with other large Specials, was recovered from new Mining Block 4, which is an area planned for resource delineation in 2018 to be included in the alluvial JORC resource update. This Mining Block is located close to the treatment plant. The frequent recovery of large and premiumvalue diamonds from new areas along the Cacuilo River valley continues to illustrate the uniqueness and potential of the Lulo diamond concession, said Wetherall. Thus far, Lulo has already recovered 10 +100 carat diamonds to date, including Angola’s two biggest recorded white Type IIa gems weighing 404 carats and 227 carats. 2

Laúca Hydropower Plant, set in the Kwanza river with a total capacity of 2,070 MW, it is about to become the largest hydropower plant in Angola. The third power generation group will be commissioned this April, bringing the current installed power to over 1,000 MW. With these three generation groups in full operation, out of a total of six, Laúca has already consolidated as the largest hydropower plant in Angola, surpassing the installed capacity at of Capanda (520 MW) and of Cambambe (960 MW) Hydropower plants. When the sixth generator set - being currently assembled - comes into operation, Lauca will reach an installed capacity of 2,070 MW, becoming one of the largest hydropower plants in Southern Africa, alongside the Cahora Bassa Hydropower plant, in Mozambique. As it produces clean and renewable energy and contributes to the stability of the national electricity system, the Laúca Hydropower Plant is simultaneously filling the largest reservoir in the country. It is forecasted the reservoir will reach its maximum level by the end of April, ensuring - by a fair safety margin - an energy supply capacity for the next dry season scheduled to occur in the second half of the year.

Zimbabwe Zimbabwe makes a U-turn on mandatory listing for foreign firms Apparently buckling under pressure from the lobby group, Chamber of Mines, the government of Zimbabwe will drop the requirement for mining companies to list on the local stock exchange from the new Mining Act, Sibusiso Moyo, the country’s foreign minister, said yesterday, during an event in London. Addressing participants at a Chatham House event in London, Moyo, assured, “Previously there was an indication that the new Mining Act would have a requirement to list on the local exchange. But we can assure you that this qualification will be taken out." The administration of the Zimbabwe’s new President, Emmerson Mnangagwa, had introduced the listing requirement in a bid to boost investment and local ownership of the country natural resources.

Zimbabwe's foreign minister, Sibusiso Moyo

Mining group De Beers will launch pilot a programme named GemFair to create a secure and transparent route to market for ethically-sourced artisanal and small-scale mined (ASM) diamonds in Siera Leone, the company announced. The program will use dedicated technology to record ASM production at mine sites that meet demonstrable ethical standards, with the aim of purchasing rough diamonds from approved locations while helping improve working conditions and livelihoods for those working in the sector. De Beers is partnering with the Diamond Development Initiative (DDI) for the pilot project, a Non Governmental Organisation that has been leading efforts to formalise the diamond ASM sector in several parts of Africa. According to terms of the agreement, miners that wish to participate in the GemFair pilot must be certified by the DDI as meeting their standards, as well as additional standards specific to the GemFair business model. The pilot project will run in Sierra Leone ,where a number of artisanal mine sites are already participating in the DDI’s Maendeleo Diamond StandardsTM programme and where the Government of Sierra Leone has made significant advancements to formalise the ASM sector. The pre-pilot phase of GemFair will involve setting up a local presence in Sierra Leone and working with the DDI and registered mine sites to ensure the agreed standards are being met, that participating miners are trained in how to use the technology solution, and that they have an understanding of diamond classification. May - June 2018


Turnkey demolition specialists

Turnkey demolition specialists By taking a holistic and practical approach to demolition activities, Jet Demolition has developed and patented a range of highly specialised demolition tools and methods with the primary goal of executing the work safely.

Jet Demolition has developed and patented a range of highly specialised demolition tools and methods

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et Demolition (Pty) Ltd offers turnkey demolition solutions to Heavy Industrial and Mining sectors. The company’s innovative, technically advanced methods and state-of-the-art equipment enables them to take on the most complex heavy industrial demolition projects. By taking a holistic and practical approach to demolition activities, Jet Demolition has developed and patented a range of highly specialised demolition tools and methods with the primary goal of executing the work safely. Jet Demolitions’ fleet is in excess of 60 items of mobile demolition plant, ranging from a 1 tonne skid steer unit to a 102 tonne high reach excavator with a reach of 35

meters. The specialized demolition work tools for their modified excavators include hydraulic shears, hydraulic hammers, crushers, pulverisers and various other attachments with quick-change mountings. Jet Demolition offers a range of specialized services, each carefully selected to the project at hand. Their abilities include cold-cutting and flame-free methods, specifically developed for the Petrochemical Industry, as well as high reach demolition, enabling top-down demolition of multi-story structures without the added risk of working at heights. The company also offers turnkey demolition solutions to the mining industry,

May - June 2018

including Shaft Capping, full and sectional plant demolition, rehabilitation of mining sites, decontamination of radioactive and contaminated areas, shaft closure and capping, and revegetation to a natural grazing state. Their professional team also regularly undertakes demolition costing and estimating for mining clients, thereby ensuring sufficient long-term mine closure planning. Jet Demolition operates throughout Africa, and has successfully completed projects in 11 countries. Their long-term commitment to safety and technical excellence helps strengthen Jet Demolition’s position as Africa’s Premier Demolition Company.

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Packaged Waste Heat Recovery Boilers

Offsetting rising energy costs John Thompson demonstrates practical ways by which mine operators can turn waste heat into thermal energy and offset effects of rising energy costs on the bottom-line, through the use of packaged waste heat recovery boilers.

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ohn Thompson, a division of ACTOM (Pty) Ltd, is the largest boiler manufacturer on the African continent, has supplied many fuel-firing and waste heat boilers to the mining industry since commencing manufacturing in Cape Town in 1954. The company’s waste heat recovery boilers are generally custom designed units that are matched to the requirements of customers both in South Africa and export markets. With the current drift towards energyefficiency and environmental sustainability, African Mining Brief gathers from John Thompson’s Export Manager, Simon Boiskin, how the company has stayed relevant and how waste heat boilers are key to meeting pertinent industry power needs. Enthusiastically, John Thompson’s Export Manager, Simon Boiskin, narrates how the company has managed to cope with the changing waste heat requirements in the industry, singling out the use of advanced technology as a critical factor. “Our large and experienced team of engineers uses a number of internally developed and external computational tools to optimise the design of the boiler, including computational fluid dynamics (CFD). CNC technology is used in the drilling of waste heat boiler tube sheets. The accuracy of the drilled holes allows for precise fitment of hexagonal head ferrules to the boiler tube plate. The use of specialised ferrules reduces the maintenance requirements associated with refractory,” he relates, indicating that, depending on respective customer’s capacity requirements, John Thompson offers boilers with an internal steam space or separate steam drum. Through Simon’s approach, he stresses, customers can be assured of a high quality product with full material traceability and focused quality control throughout. The niche of waste heat recovery boilers Another factor that has made John Thompson a go-to company in the provision of industryspecific industry boilers is consistently rising awareness about the benefits of waste heat recovery boilers to potential customers. This approach is steeped in the notion that it is important for mine operators to be conversant with the basics of a waste heat boiler in order to make informed decisions in 4

Enviropac TE1200 Front Right

Simon further notes that any high temperature gases being discharged could indicate a potential loss of energy, even if steam is not required. “If steam is not required for process heating, then electricity could still be generated through waste heat recovery. Should hot gas be produced on site in any substantial quantity that is not being recovered, this could be an application for a waste heat boiler. If the site does not have a use for the steam generated, the steam can be used to generate power through turbine or expander technology,” he states. “At the same time, lower temperature exhaust gases will be discharged to atmosphere. It is also possible to recover heat from the exhaust gas of large diesel generator sets and generate steam or hot water. This would improve the overall system efficiency.” Power generating screw

Europac TU1050 Front Right

their procurement decisions. Bringing out the significance of waste heat boilers to mine operators, Simon expounds, “The primary function of a waste heat boiler is to recover heat from gases generated through mining operations and generate steam from the heat whilst cooling the gases. In certain cases, gases are produced as a result of the process, such as heat from smelters.” As an example, Simon draws attention to the production of sulphuric acid as a potential source of power. Hot gas produced during the production of sulphuric acid (which is used for leaching), which involves the combustion of sulphur to form SO2, can be used in power generation. The gas is cooled through a waste heat boiler from temperatures in excess of 1,000°C to temperatures below 400°C. Later, the gas is processed to form SO3, and ultimately sulphuric acid. The heat released from the process gas is absorbed by the boiler water and generates steam. The steam is used for process heating of slurry or even first for generating power and subsequently process heating.

expanders John Thompson will be introducing a range of power generating screw expanders that act as a pressure reduction station for saturated steam and generating power as a byproduct of the pressure reduction. The screw expanders can be applied in areas where a pressure reduction of at least 2:1 is required. Flexibility and location central Recently, John Thompson demonstrated its flexibility in meeting customers’ needs in the manufacture of a 40,000kg/h waste heat boiler operating at a pressure of 43bar. The boiler, with a typical manufacturing period of 8 top 10 months, was completed within 4 months for an emergency replacement project. The boiler had dimensions of 2.55m diameter and 5.5m long, with a weight of 60tons. Over and above flexibility in attending to client’s demands, another benefit that companies in sub-Saharan countries have is John Thompson’s strategic location. “Depending on the location of the site, equipment can be transported by either road freight or sea freight. This is especially useful when considering the abnormal size of much of the equipment supplied to the mines,” assures Simon. May - June 2018


Conveyor gas detection

Timely detection for effective mitigation It is paramount for mines to maintain high standards of housekeeping in and around conveyors to prevent the accumulation of spillage and waste that could potentially result in a catastrophe, writes MATIMU MAHUNDLA. The principal source of fire in coal mines is the combination of gases of materials being conveyed and the belt itself

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reas surrounding conveyors are required to comply with the requirements of the Mining Health and Safety Act due to the high risk of fire explosion that they face. For instance, conveyor enclosures and supporting structures such as conveyor belts can burn as a result of friction from misalignment, overheated motors and burning material on them. Coal mines In a report, the Fire Protection Association of Southern Africa (FPASA) mentions coal mines as one of the high risk areas prone to a fire outbreak. “Coal mines conveyors are subject to two main types of gases causing fires, methane and coal dust explosions.” The principal source of fire in coal mines is the combination of gases of materials being conveyed and the belt itself, points out

FPASA. “Methane explosions occur in mines when a buildup of methane gas, a byproduct of coal, comes into contact with a heat source, whilst there is not enough air to dilute the gas to levels below its explosion point. In addition, explosions can be triggered when fine particles of coal dust come into contact with a source of heat.” Fixed set of rules only not enough Actually, gases that cause explosions and fire on industrial installations such as conveyors are unique and cannot be controlled using only a set of fixed rules. That is why there are a range of different types of fit-for purpose gas monitoring systems that are used at various mining enterprises. Such include portable gas detection devices primarily used by mining personnel for routine inspections and monitoring during operations.

Control measures It is paramount for mines to maintain high standards of housekeeping in and around conveyors to prevent the accumulation of spillage and waste that could potentially result in a catastrophe. The burden of responsibility entirely lies with mining companies, as they bear the consequences of an accident. Solutions are readily available from OEMs. Original Equipment Manufacturer, Schauenburg, provides GDI Intellisens Fixed Single Gas Monitor instruments that monitor and accurately determine presence of gases such as as hydrogen, ethylene, acetylene and other gaseous products of combustion. Its robust enclosure makes the Intellisens suitable for harsh conditions which can be found in the mining industry, plants/factories as well as chemical laboratories.

We innovate to make mines safer and more productive.

Location Monitoring

2-way paging & distress call

Collision Awareness

Roxy 40 Self-contained self-rescuer

Portable gas detection instruments with “reactive time” communication up-links.

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Fully integrated system that can download gas readings, track people, assets & vehicles, collect telemetry data, transmit paging messages and collect SCAS II - Collision Awareness logs. New generation Caplamps including wireless and digital communication, worn by the underground worker. SCAS II Collision Awareness System, providing early perimeter warning notification that gives vehicle operators and pedestrians a head start in deciding how to manoeuvre during or before a critical decision making period. The Roxy Self Rescuer is a belt worn breathing apparatus to exit from hazardous zones. Its intended use is only in the case of emergency escapes in the event of smoke, toxic gas and oxygen deficiencies.

011 974-0006 | www.schauenburg.co.za Schauenburg Systems (Pty) Ltd.

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A company of the

International Group

May - June 2018


Gratings for walkways

VITAL Safety Support Vital Engineering goes all out to address client requirements, and constantly seeks new ways of improving quality and safety in their product portfolio of gratings, stair treads, pressed floors and safety handrails.

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n over six decades of existence – having celebrated its 60th anniversary in 2017 Vital Engineering has thrived through a ‘demand-based’ approach to addressing the requirements of a diverse clientele in various sectors, from petrochemical, industrial and power generation to mining and many others. For the company the old adage ‘necessity is the mother of invention’ rings true, and has resulted in several highly innovative product development ‘firsts’ and patents - such as their renowned non-slip serrated gratings and angle stanchions to name but two. Steeped in this ethos and practical, innovative approach to producing products which effectively address client’s on-site challenges, Vital Engineering has developed and manufactured a wide portfolio of both bespoke and standard issue safety products for flooring, hand railing and grating applications (including ‘work-at-height’ requirements) spanning various industries. One sector where the company is very passionate about helping clients to solve complex problems is mining, Technical Director, Glen Pringle, tells African Mining Brief. “In the course of working with mining companies, over the years, we realised that, without proper walkways, convenient access becomes a challenge both in terms of safety and operational efficiency in minerals processing plants and ore handling facilities, which have various levels of elevation off the ground.” Vital Engineering has consequently produced a range of products of premier quality which are now found on a growing number of mining operations throughout Africa and other parts of the world. The company specialises in a range of fully serrated, multi-directional non-slip floor gratings and stair treads, providing a durable, corrosion-resistant and aesthetically pleasing solution for its customers. Under the brand names Vitagrid, Vitaglass, Vitex and Vitacon, Vital Engineering’s products have been used extensively in large and small mining projects over many years. Quality compliance and innovation As an ISO 9001 entity, Vital Engineering is aware that mining companies are very strict about safety, in view of the high risks that mineworkers are exposed to daily, and the attendant human capital and operational

costs incurred should an accident occur, states Pringle. “We ensure strict material controls for our products, which results in the benefits not only of minimising lost time injuries (LTIs), but of lowering maintenance and operational costs, and extending life-ofmine .” In addition, mines are constantly obliged to comply with new safety regulations and at the same time ensure that their operations are sustainable. Through their extensive experience in supplying the local, panAfrican and international mining sectors, Vital Engineering has been able to achieve excellent results in what has become, by definition, a rapidly changing and demanding sector. Positive feedback Vital Engineering revels in seeing its product portfolio such as its non-slip serrated gratings and safety hand railings making a huge difference to safety on mines. Pringle proudly reveals that the company has repeatedly received positive feedback from mining companies in terms of significant reductions in the number of accidents caused by slippage. “Reduction in the number of accidents translates into a reduction in the number of employee compensation claims, legal repercussions and the risk of compulsory shutdowns and resultant downtime.” ‘Vital’ features The unrelenting pressure to enhance productivity and increase revenue places a huge strain on both run-of-mine and miners, unwittingly causing high safety risks, not least in walkways where there are large volumes of foot traffic. Accordingly, Vital Engineering designs walkway and hand railing systems that are more than able to cope with the sometimes extremely harsh environmental and demanding operational conditions found on mining sites locally and pan-Africa as well as internationally. With confidence in the quality of Vital Engineering’s fibreglass Vitaglass gratings, Pringle describes the features which make the products ideal for mining. “Vitaglass grating is manufactured from continuous glass fibre strands and resin. This makes this grating lightweight and easy to install, which in turn makes it suitable for a number of varying applications such as walkways, platforms, trench covers and mezzanine structures,” he

May - June 2018

elaborates. “Made of fibreglass, Vitaglass gratings are completely corrosion-resistant which makes them very suitable for use in high-corrosion areas; or on plants that use highly corrosive chemicals. Apart from being corrosionresistant, Vitaglass gratings are also nonconductive, non-magnetic and require almost no maintenance. Most importantly, Vitaglass gratings are either fire-resistant or fire-retardant, depending on the specification,” he adds. What's more, Vitaglass gratings are available in various grating depths and in mesh sizes, to suit various loadings and specifications. Custom-built commitment Ore bodies vary from mine to mine and thus metallurgical processing plants differ in their dimensions and design. And pertinently, with a dynamic mindset, Vital Engineering is able to deploy walkways quickly and easily. Vitaglass (or other metal) gratings are supplied in modular panels complete with custom securing attachments (Vitaclamps) for easy installation. Should a walkway need to be expanded or altered, with Vitaglass (or other metal) gratings and Vitaclamps, this is quickly and easily done. Further to this, Vital Engineering’s modular walkways and hand rails cater for new-generation (alluvial-type) mines which – by their nature - have comparatively short operational lives. The walkways therefore can quickly and easily be dismantled and reerected at new sites. In addition to fibreglass, the company offers products in many ranges including various grades of steel and stainless steel. Vital Engineering also does its own in-house digital (CAD) design; and has the facilities to do pre-trial layouts at its Boksburg manufacturing facility, to ensure that final assembly on-site is faultless, thereby minimising any costly and time-consuming rework. As a company, Vital Engineering goes all out to address client requirements, and to seek new ways of improving quality in safety walkways and gratings and hand rails. 7


Mine Communications infrastructure

Life-saving messages delivered instantly through metal Using any metal infrastructure in underground mines, Kutta DRUM® medium frequency radio systems can effectively warn every miner of a developing disaster and save lives.

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dvanced Comms Limited, a South African company, may have unlocked the missing piece in the provision of effective communications in the underground mining environment, which is extremely volatile and miners are exposed to many dangers such as rock falls, toxic gases, explosions, and fires. Typically, traditional communication networks have a common shortcoming: they only work in developed areas of the mine, not undeveloped areas where blasting and digging takes place. However, to workers in undeveloped areas, the only source of communication is the shift supervisor or related personnel. Moreover, while the traditional communication networks in underground mines may comply with the requirements of the Mine Health and Safety Act (MHSA), a mine operator may be liable for the loss of workers’ lives due to consequences of failure to provide adequate communication. Kutta DRUM® radio systems Advanced Comms’ Kutta DRUM® radio system provides next-generation medium frequency radios to mine operators as a reliable, cost-effective solution to communication and tracking needs in underground mines. Yoni Margalit, the managing director of Advanced Comms, explains how the Kutta DRUM® radio system works to African Mining Brief: “The DRUM® is a wireless medium-frequency radio system that works irrespective of whether mine power is on or off, post-incident, and even through obstructions. Through converting VHF or UHF Handheld radios signal to the Kutta MF signal, the radios use parasitic propagation of medium frequency signals to send voice and data communications in an underground environment. These signals magnetically couple to metallic items commonly found in the infrastructure of a mine, and allow for voice and data transfers several kilometres away.” Robust signal What makes the Kutta DRUM® radio system unique is the signal it uses, according to 8

Miners being briefed on how being briefed on how the radios work underground

Margalit. The signal is robust and redundant, unlike leaky feeder systems, which run specialised cable and infrastructure, he stresses. “In leaky feeder systems, amplifiers must be periodically tuned, and can be easily damaged, which makes them unreliable. Even worse, with current node based systems, line of sight and narrow tunnels decrease the range. With linear systems, the situation is not even better, for instance, should one fail, the entire system fails.” Incredibly, when proper conductors such as leaky feeder cables (powered or unpowered), phone lines, power lines, lifelines, metal pipes, and tracks - are present, signals can travel for kilometres with nonline of sight. In essence, the mine becomes the antenna. Ultimately, the Kutta DRUM creates long-distance communication link between entire teams of personnel. Perfect fit for harsh environments What makes the Kutta DRUM® radio system perfect-fit for the harsh underground mining environment is its handiness, Margalit says. “Intrinsically safe, the Kutta system comes

in large durable suitcases, set-up is easy, has a smaller metal enclosure, improved battery life, and has an IEC/ATEX certification for use in hazardous conditions.” Tested in extreme conditions Mine Rescue Services, a company that distributes safety solutions to mines globally, has tested the Kutta radio system in extreme mining conditions, and several times, the system’s efficacy has been proven. This is the company’s account of the system: “We connected the Kutta radio system and decided to travel through the mine and to compare the area where we battle with communication with the Gaduza system.” The system excelled. The Kutta WARN System The Kutta WARN System, which Advanced Comms designed in conjunction with Kutta, functions through the same patented medium frequency as Kutta DRUM® radio system. Equipped with the WARN device, each individual is alerted immediately of any danger known to surface, Margalit explains. “The signal can be triggered May - June 2018


the Kutta WARN System device will be manufactured in South Africa soon, reveals Margalit. “We strongly believe that this innovative communication technology, which is to be launched soon, will contribute substantially to achieving zero harm in the mines,” says Margalit.

manually or automatically by the mines systems. The WARN device receives an emergency medium-frequency signal sent from a transmitter on surface, which is sent by magnetic induction. This means that the signal is not dependent on any communication cabling.” Demonstrating how the WARN unit works, Margalit says: “When a Miner is out of range the WARN unit will start beeping. The units alert miners to a problem by Beeping, Flashing and Vibrating.”

Empowering the miner, removing dependency on others Distinctively, the WARN device removes the dependency on others to warn the miner of danger. It can give audible, visual, and vibration warnings, providing the miner with early notification of imminent danger and the opportunity to reach a refuge bay or evacuate as quick as possible. Ultimately, the WARN device saves lives. Good news for mine operators in South Africa and neighbouring countries is that

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Communications - difference between life and death By and large, Margalit advises, “What mines should realise is that Communication is Time critical. And so, the miner has to be empowered with the right communications tools to act as swift as possible to events such as spread of smoke, carbon monoxide and rock falls. Early warning to evacuate or take shelter is the difference between life and death.” Trade union, Association of Mineworkers and Construction Union (AMCU) lends credence to Margalit’s standpoint on the significance of using the right tools in underground mines, AMCU urges the Department of Mineral Resources (DMR) to step up measures to ensure that mining houses comply with regulations.” Mining houses are not addressing precautionary measures to avoid accidents, as well as contingency plans to deal with the resultant fall-out when accidents do occur,” the organisation bemoans.

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A5 African Mining March18.indd 1

May - June 2018

2018-03-20 05:41:04 PM


Modular Steel Bolted Tanks for Mining Requirements

Bolted flexibility Easily transportable, modular designs allow for the modular steel bolted tanks to be carried to remote locations without problems and offloaded manually. Furthermore, rapid on-site installation ensures that a tank becomes ready for use within a shorter time than with ‘brick and mortar’ options.

A modular bolted steel tank on a site

T

he expression “fit for purpose” comes from executives donning designer suits in corporate boardrooms so often that it has become hackneyed. Nevertheless, in the harsh mining environment, conditions prompt industries to require new technologies that are not superfluous but fit for the exact purpose they are intended for. Relating to liquid storage in remote sites, among products that comes to mind are bunded tanks.

robust tanks. One among numerous ways through which the tanks are reinforced is through standard or heavy-duty commercial grade liners capable of standing up to most aggressive liquids are available. A favourite material for the outershell of bolted steel tanks is Zincalume® steel, which has superior corrosion resistance and offers a 60 year plus life expectancy, as well as high tensile strength.

Contemporary features In get a grip on recent trends, African Mining Brief surveyed products from manufacturers of bunded tanks that are specific to contemporary conditions in the mining environment and compiled features that are preferred.

• Easily transportable and rapid deployment Almost certainly, there is no industry where time is of the essence than in mining. Easily transportable, modular designs allow for the modular steel bolted tanks to be carried to remote locations without problems and offloaded manually. Furthermore, rapid onsite installation ensures that a tank becomes ready for use within a shorter time than with ‘brick and mortar’ options.

• Robustness The extremely harsh and aggressive conditions in mining and related environments require

May - June 2018

• Occupational Safety and Health Safety With the regulators vigilant about health and safety matters, designs that eliminate the use of lifting equipment and working at height reduce health and safety risks during construction of tanks on site. Manufacturing and erecting Modular bolted steel tanks with the abovementioned features mean nothing if they do not benefit a miner who is overburdened by the impact of low commodity prices on operations and pressure to comply with various pieces of regulation. As the expression goes: Proof of the pudding is in the eating”, a bolted tank is only effective if it serves a miner operator’s particular need. Companies that specialise in both tank manufacturing and erection bring convenience to the end-user. 11


Automatic fire suppression

Protecting your Assets from the Ravages of Fire Firetrace, the world leader in special hazard fire protection, provides both in-cabinet and machinelevel fire suppression and protection for high-value and/or mission critical machinery and equipment.

Firetrace, the world leader in special hazard fire protection, provides both in-cabinet and machine-level fire suppression and protection for high-value and/or mission critical machinery and equipment.

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utbreak of fire is the most common incident type reported for mining operations. In coal mines, fires hazards are compounded by the presence of coal, coal dust and methane. The storage of flammable and combustible liquids is an especially important concern because the materials ignite more easily and propagate fire more rapidly than ordinary combustibles. Firetrace, the world leader in special hazard fire protection, provides both incabinet and machine-level fire suppression and protection for high-value and/or mission critical machinery and equipment. Due to Firetrace detecting and suppressing the fire instantly at the source of the hazard, a growing fire can be caught quickly, preventing the spread of fire to other parts of the building or machinery that would require firefighters or water sprinklers to extinguish. Fire protection for mining vehicles and equipment Firetrace offers a unique solution for

protecting all types of mining equipment against the risk of fires. The heart of the Firetrace system is the company’s unique, pressurized Firetrace Detection Tubing (FDT), which can be routed in and around the hazard areas of mobile and electrical mining equipment. The heat-sensitive tubing is designed to burst when exposed to a fire’s radiant heat, which automatically triggers the release of the fire extinguishing agent. Firetrace systems are compatible with most commercially available fire suppression agents, including “clean” extinguishing agents such as Chemours FM-200 and 3M Novec 1230 as well as CO2 and ABC dry chemical powders, ensuring the best agent can be chosen for any particular application. Fire protection for heavy offroad equipment Many industries utilize expensive, heavy off-road equipment. This equipment, while functionally very reliable, can be susceptible to elements of the working environment.

Fire protection for commercial and industrial electrical enclosures

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Over time hoses can fatigue and fail, or leaves, twigs and pine straw can build up on the machine and often accumulates in the engine compartment or other hazardous areas. The heat of the engine and exhaust systems can easily ignite the leaking fluid or dry materials, leading to a fire that can envelope the entire machine. In some cases, additional liability arises from a potential secondary grass or wildfire. Firetrace automatic fire suppression systems were designed specifically for the harsh environment of off-road vehicles. In spite of working conditions that would cause other fire systems to fail, Firetrace’s unique design enables it to endure the shocks and vibration associated with the operation of these off-road machines. Fire protection for commercial and industrial electrical enclosures Electrical control panels can be found in virtually every industrial and commercial space. In some cases the electrical enclosure might be a single small panel, in others it might be a large room filled with electrical control cabinets. The greater the number of enclosures, the greater the potential for wire fatigue, overloaded circuits, power surges and equipment failures to cause a fire. Should a fire occur in an electrical enclosure, it would typically destroy the contents; left unchecked, the fire could spread to parts of the room or the building structure itself, causing downtime and threatening lives and property. By containing the damage to the individual electrical fire panel, damage is limited to that enclosure and the collateral damage often caused by traditional fire suppression is avoided. Firetrace cabinet fire protection systems act quickly in order to minimize damage and ensure the safety of your equipment as well as anyone in the vicinity. In Southern Africa, Firetrace is distributed, installed and maintained by Trysome Auto Electrical (Pty) Ltd. May - June 2018


Automatic explosion suppression systems

Snuffing out danger instantly, saving lives 16 years

EXPLOSPOT® Automatic Fire and Explosion Suppression System detects and suppresses an explosion instantly, creating a full barrier, saving lives and invaluable assets which would have otherwise been lost.

...since the first methane gas explosion was suppressed by an ExploSpot Automatic Explosion Suppression System in a South African coal mine. Since then further methane gas and coal dust explosions have been successfully suppressed at the cutting face by our explosion suppression systems.

Spaeth demonstrates how EXPLOSPOT® works, “Once an explosion is ignited, detected and suppressed instantly, full barrier is created, lives and invaluable assets are saved.”

EXPLOSPOT® called to action

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• Extremely effective • Ultra high speed • Robust • Reliable • Customizable • Mobile

Fire and Explosion Suppression Systems

High quality OEM and service provider.

012 940 8305 www.explospot.com contact@explospot.com 14

ethane gas and/or coal dust explosions that have been extensively documented in the past forty years have established, beyond doubt, that methane gas is one of the biggest safety hazards in coal mines. As you would expect, by now, with this information, coal mines should be adequately prepared to prevent and control risks associated with mine explosions. However, the biggest concern is the effectiveness of the measures. Worryingly, many of the measures used are under the control of man, which creates huge margin for error. There is no other option in effectively managing the hazards of a methane explosion in coal mines apart from using effective explosion suppression solutions, Arend Spaeth, Chief Executive Officer of ExploSpot Systems (Pty) Ltd., reasons African Mining Brief. “When it comes to the safety of employees in underground environment there should be no compromises. You can’t take chances with people’s lives.” EXPLOSPOT® Automatic Fire and Explosion Suppression System Beyond question, as explosions occur rapidly, suppression products should be able react instantly. “An explosion occurs in a millisecond and, accordingly, companies should be able to react rapidly. Otherwise, a minor delay can result in loss of assets and people’s lives,’ cautions Spaeth, informing coal mines in Southern Africa about EXPLOSPOT® Automatic Fire and Explosion Suppression System, an active barrier solution for harshest environments.

Safety compliance Locally designed and manufactured to high standards, EXPLOSPOT® systems tick all the boxes in terms of safety requirements for explosion mitigation in mines. Mainly, Spaeth underscores the following standards designed for continuous miner installed systems: • Designed to meet the requirements of the European, Chinese and South African flameproof and performance standards, IEC 60079-0-1 and IEC 61000-6-4 respectively. In addition, EMC according to EN 61000-6-3 and 61000-6-4 • Flame propagation limited to save operator • Pressure shock within human tolerance • Temperature within human tolerance • False alarm immunity • Re-operable within 8 hours These systems therefore meet requirement sets out in the DMR directive (D. Mzisa 2003), with respect to autodetecting and suppressing flames resulting from frictional ignitions in burnt coal. General applications Independent and self-contained, EXPLOSPOT® systems automatically detect explosions and react rapidly. With EXPLOSPOT®, the safe working area is from the face, flame propagation is limited to approximately seven metres. EXPLOSPOT® systems can be deployed in the following areas: Long wall installations, roadway barriers, and mounted on machines such as continuous miners. These installations are installed through a special agreements with original equipment manufacturers (OEMs) and the requirements determined by a mine. ExploSpot Systems Pty Ltd. also provides preventative monitoring, warning and fire protection specific to conveyors, transformers and switch cabinets.

Read More of this article on: http://ambriefonline.com/ May - June 2018


Fail-safe braking systems

Brakecore Supply Tpfc.pdf 1 5/11/2018 3:00:01 PM

Fail-safe braking systems

ABT Failsafe. High Performance Brakes for the Harshest Environments.

Mine operators can benefit through cost savings in reduced maintenance costs and increased productivity of braking systems in vehicles on site through ABT Failsafe and Terra Dura brakes.

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he direct and indirect impact of vehicle downtime due to brake failure cannot be easily quantified, but the undeniable fact is that the loss of productivity can translate into a loss of revenue running into tens of millions of dollars. Allan Hawley, the managing director – the operations officer of Brakecore Supply Company, an organisation that supplies braking solutions to various industries in South Africa and sub-Saharan countries, has been documenting data from various industries. From what he has ascertained is that, the main reason the problem of brake failure is common could be low awareness or sheer negligence about the shortcomings of using standard braking systems in vehicles. “Standard braking systems simply aren’t designed for the harsh operating conditions found in the mining industry. Due to often muddy, dusty and environments where the surface water in the mine can be significantly corrosive, standard OEM brakes simply can’t cope with these conditions and can sometime wear out in a matter of weeks also contributing to potential safety risks,” he clarifies, mentioning another significant limitation of some OEM brake systems as the inability of the hand/parking brake to work effectively.

housing and don’t incorporate an emergency brake, Hawley underscores. “The failsafe brakes, as the name eludes, incorporate a ‘failsafe’ brake that can be operated in case of an emergency / vehicle runaway. Moreover, ABT FailSafe and Terra Dura brakes incorporate Hand Brake protection giving the operator a comfort that the hand brake is always going to work and hold.” ABT brakes’ high quality components, which include a single Monoblock design caliper and special grooved brake pads, also contribute to the longevity of the brake. In addition, the brakes improve the life of wheel bearings, as they are protected by the sealed braking system. More importantly, mine operators can benefit through cost savings in reduced maintenance on braking systems, in addition to less downtime for vehicles, increasing mine productivity. C

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The alternative Allan Hawley is familiarising mine operators in African countries about its FailSafe ABT Failsafe and Terra Dura solutions that eliminate shortcomings of standard braking systems, underlining the qualities that make the two products suitable for mining vehicles.

Brake range Brakecore’s principal manufacturer and supplier, ABT, has a range of brakes to suit a number of applications, including: • Wheel end brakes, as well as driveline brakes for a range of vehicles, such as Land Cruiser 70 Series and Toyota Hilux range; • Terra Dura and Failsafe, driveline brakes to suit Hino, Fuso, Isuzu Mack and Kenworth trucks • The new Terra Dura models in development for Toyota Hilux, Isuzu DMax and Mitsubishi Triton.

Failsafe features According to Hawley, both the ABT Failsafe and Terra Dura brakes are fully sealed, preventing any contaminants from entering the braking system and causing physical damage to the brakes or from corrosive mud and water from attacking the exposed components. The most outstanding feature of the ABT Terra Dura brakes is that they are manufactured from a lightweight polymer

Key decisions Hawley reminds mine operators to consider local regulations and laws pertaining to braking systems. “Countries like Australia and South Africa mandate that underground vehicles must have an emergency / Failsafe braking system,” he points out, recommending either an ABT FailSafe brake or the New ABT Terra Dura brake for addressing failsafe braking demands.

May - June 2018

• Chosen by the world's biggest mining companies • Fully sealed brake for retro fit in multiple vehicles from light SUVs to trucks and trailers • Mandated for use in many underground mines • Fail safe brakes with exceptional reliability • Excellent durability means low maintenance costs • Zero emissions = environmentally sound

William Robb Tel: 083 839 3862 Office: 011 826 3640 Unit 1A, Lakeview Bussiness Park , Yaldwyn Road, Jetpark

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SideVacserv channel Tpfc.pdf 1 blowers 4/23/2018 3:44:51 PM

Greenco blowers made for most demanding tasks Key components

• Motor Greenco blowers are available ex-stock Wadeville, in 220v from 0.2kw single stage units to 2.2kw single stage units, 220volt double stage units are available from 0.7kw to 1.5kw. • Shaft Seal Maintenance free shaft single lip seal is installed between the motor and blower • Silencer The inlet and outlet are fitted with a silencer as a standard

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• Casting Hi precision aluminium castings are used with ease of access to the motor and blower for inspection and maintenance.

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• Instruction for operation Side channel blowers are constant volume machines and do not react favourably to excessive intake or discharge restrictions. Always insure the application allows for installation of a relief valve on either intake or discharge depending on the required duty. Good practice also suggests the installation of inline filters to insure longevity of the machine by handling clean solids free air.

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• Easy to install Greenco blowers really are a complete unit ready for immediate installation either as a vacuum pump or as a blower. The unit can be mounted in any position, horizontally or vertically. • Greenco Reliability Greenco side channel blowers are reliable machines with a very good reputation in Africa for dependability and rugged design. Used in applications such as agitation, aeration, ventilation as well as widely used in the plastics manufacturing industry. Apart from the traditional close coupled motor and blower design, Greenco also manufactures a bare-shaft unit able to be fitted using a coupling direct or driven via V-belt arrangement to drive at higher than the standard 2 pole speed. 16

• Mode of operation The impellers in the G-series machines are mounted directly on the motor shaft for noncontact compression entirely without friction. Maximum operational reliability, even at high differential pressures is ensured by the arrangement of the bearings outside the compression chamber. Centrifugal force in the impeller blades accelerates the gas outward and the pressure increase. Every rotation adds kinetic energy resulting in the further increase of the pressure along the side channel. The side channel narrows at the rotor, sweeping the gas off the impeller blades and discharging it through the outlet silencer, where it exits the side channel blower. • No Oily odours The impeller rotates with absolutely no contact between it and the housing. This means no lubrication is required, guaranteeing 100% oil free operation. • Quality Under serious QC Control and with over many years’ experience, the parts used in Greenco blowers are three dimensionally checked and only passed if tolerances are within strict Greenco standards. May - June 2018


Water-cooled copper components for furnaces

Cost saving via copper cooling Through using copper as a cooling component in a refractory, a refinery can achieve considerably cost-savings, through minimising downtime, caused by replacing refractory lining, at best, and damage to the refractory shell.

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asic metallurgical It has to be replaced regularly, principles of smelting and results in process downtime involve applying heat and repair and replacement costs. energy to a metallic ore using a An alternative would help a great flux and a reductant to extract deal. the metal from its naturally occurring oxides. Temperatures A cooling mechanism could vary from 1,000⁰C to Alternatively, by using a 1,800⁰C. At these temperatures, cooling mechanism to lower the most furnace shells would melt contact temperature between the lining and the melt zone, a away with disastrous results. So, unsurprisingly, one of the substantial saving in costs per biggest expenses in a furnace is ton melted is achieved. Also, the the compatible lining of a shell, cooling mechanisms acts as an commonly made of steel and additional safety factor in almost copper, which protects the shell eliminating the incidence of runfrom heat and the corrosive and outs or burn-throughs. melt erosive melt environment. The lining forms a major cost Copper as a cooling and safety aspect in the smelting element process as it is a consumable Copper is the logical choice for ThosBegbie Tpfc advert.pdf 1 5/11/2018 11:04:00 AM item subjected to wear over time. the cooling component as its

general physical properties and cost-versus- thermal conductivity efficiency is the best of all known materials for this application. In order to create an efficient heat exchanger or cooling element, water is circulated through the copper by means of a network of drilled holes in a copper slab, or an inclusion of a Monel (nickel/ copper alloy) pipe circuit, cast into the copper casting. The volume and velocity of the water coolant is controlled to achieve the perfect balance of creating an effective freeze-lining, yet not losing too much heat energy from the smelt reaction zone. The essence of efficient cooling is achieved by obtaining a 100% bond between the cast copper and the Monel piping,

so that maximum heat transfer can take place. Efficient heat transfer takes place between the highly conductive pure (“4 x nines” copper) through the corrosion-resistant nickel/copper (monel-400) tubing, where treated water removes the correct and balanced amount of heat in a closed-circuit to the water cooling- towers. Less downtime and low-cost savings Indeed, through using copper as a cooling component in a furnace, a refinery can achieve considerably cost-savings, through minimising downtime, caused by replacing refractory lining, at best, and damage to the refractory shell.

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PPE vending machines

Safety equipment right at the miner’s finger tips

The vending of Personal Protection Equipment (PPE) has brought positive changes to the mining sector by compelling the mineworker to be personally responsible for his/her safety.

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• It is a great tool for job costing and it enables our customers to dramatically reduce consumption and abuse, simply because employees know they are accountable for what they use. • Plug in and start saving at least 30% • No more tracking down supervisors, travelling to remote storerooms, or handing out repetitive items. • Increase productivity by making products available 24/7 at the point of use - employees can self-serve and get back to the job in a matter of seconds. • Although the product is easily accessible, every transaction is controlled and tracked. • Complete control over the issuing of items – who may vend and how often. • The level of control in reporting is completely up to each company. • View detailed usage data to drive continuous improvement – full and flexible management reporting available.

ontrary to popular perception, vending machines are not just for snacks, drinks coffee or healthy foods anymore. In fact, Leon Fensham, the managing director of Dispenstech Solutions, notes that over the past 10 years, and more recently in South Africa over the past three to four years, PPE vending became more and more important and common within the mining, manufacturing and construction industries. Dispenstech Solutions is a South African based supplier of vending solutions to various industries in South Africa as well as neighboring African countries. “Over the last few years, we have observed a growing shift towards large mining and industrial companies throughout South Africa placing personal safety in the workplace at the forefront of priorities. Executives within the mining and industrial/ construction industries are obliged to have all systems, processes and procedures in place to keep their staff safe in order for them to be able to return home safely to their families.” Fensham says. It should not be surprising as to why PPE vending systems have become a standard in many workplaces, states Fensham. Actually, by having a Safety/PPE vending machine at the workplace, a company makes a bold statement about its compliance to OHS, enhancing the safety of the workplace and improving its image. Significant savings Installing PPE vending machines can represent a significant saving of up to 30% in overall spend on this indirect category, Fensham points out. In particular, he elucidates, saving is a direct result of accountability as the mining company’s staff are aware that their usage of all products in the vending machine is constantly monitored. An increase in efficiency among workers, as well as reduced waste and higher productivity provide significant savings throughout a company’s production areas, he adds. “Since PPE distribution is monitored, employees using PPE from a vending program refrain from making poor choices and are less likely to abuse equipment. This represents a significant cost saving for the company in the long run.” 18

PPE vending machines on a site bring the convenience of access to Personal Protection Equipment (PPE) at the employee's fingertips

The convenience of vending Vending is the answer to cost savings in the current mining environment. Companies are seeking technology that will enable them to contain costs and increase efficiency. Essentially, it is handy in the following ways: • Gives the best of both worlds: immediate access along with complete accountability. • Eliminates tedious paperwork, stockouts and no need for you to carry excess inventory.

Where can these machines be used? PPE/Industrial vending machines can be used at any company that is trying to reduce cost without sacrificing employees’ safety. These vending machines has a wide range of applications, Fensham underscores the main ones. First, the access system currently in use on site is linked to the vending machines. Therefore, no extra cards are issued as the employees will use their existing clock cards or fingerprints. Second, the client is able to configure settings and add employees to the database via the network from his desktop. Additionally, the client has the ability to program or assign employees via the network to either one specific vending machine or all vending machines. Third, the client can create certain groups and assign products and employees to these groups. These employees will then be limited to vend specific products used by this group only. Fourth, the client can limit the number of products per employee. These limitations will then automatically pertain to all vending machines. In other words, if the employee received a product from one machine, he May - June 2018


PPE vending machines

will not be able to go to another machine and vend the same product if he is limited. Last but certainly not least, the client can also allow the employee(s) to exceed his limits for certain important PPE products. The client can then access a report that will provide details on who exceeded their limits. New trends In other countries like China, USA and Europe, companies are aware about the convenience and wide application of vending machines. Vending machines are being utilized everywhere to sell different types of products and people can access machines anywhere they are at that specific moment. On the other hand, there is need of a mind shift in South Africa, a relatively new market, in terms of embracing the convenience of PPE vending, Fensham suggests.

As a final point, Fensham has some advice to mining companies in respect of using vending machines. “Companies should realize that vending machines are there to help them save on money, man-hours, and to increase productivity. The vending machines streamline the process of issuing products to their employees,” he says. Consequently, Fensham urges companies to first look at the specific products that they want to issue to their employees and then work from there. He proposes two scenarios: either, the company can either stock the machines themselves or work through a PPE supply company that can stock the machines for them. Most importantly, he says, companies must do their homework on the PPE vending machine supplier so that they get and pay for a product that will do

Dispenstech Smart Store The Dispenstech Smart Store can stock all types of PPE like earplugs, glasses, dust masks, respirators and cartridges, gloves, belts, disposable overalls, consumables, socks, shoe covers, in other words all the repetitive items people frequently use. Hard hats, safety boots and overalls are however items that can't be dispensed. There are too many different sizes and the items are too bulky for the vending machines.

everything that they need it to do. The most important point to note is that the vending machine is a ‘dumb device’, Fensham cautions. “It is all about the software on the machine that will tell the vending machines what to do and when to vend. Unfortunately not all software packages currently used in South Africa have the ability to set restrictions on the number of vends (to limit an employee to have one pair of safety glasses every two weeks) on all the machines on site. It defeats the purpose when an employee is limited to one specific PPE product but he can vend once on every machine on site which will all give him the same product. The software must limit him so that if he received the product at one machine he will not be able to vend again at any other machine on site.”

What Dispenstech Solutions offers Fensham says that it is hard to imagine a more efficient supply process and would like to reiterate that “the Dispenstech Smart Store ensures that employees have the right products available at their fingertips. When inventory runs low, the person responsible for stocking the Dispenstech Smart Store receives an automated alert to refill. Dispenstech Solutions link the access system currently in use on site to the vending machine(s). Therefore, no additional cards are issued as the employees will use their existing clock cards or fingerprints.”

Solutions Through Focus and Commitment

JB SWITCHGEAR SOLUTIONS 5 REASONS WHY YOU SHOULD PLACE YOUR NEXT ORDER FOR SWITCHGEAR FROM JBSS

A proudly South African company. Our ‘Eagle series’ switchgear system carries type-test certification for compliance with relevant IEC and SANS standards. ISO 9001:2008 listed for our quality management system. Level 3 BBBEE contributor. We have a very good understanding of the market, our customers, and challenges facing our industry.

011 027 5804 info@jbswitchgear.co.za www.jbswitchgear.co.za 20

4b Molecule Road Vulcania Ext2 Brakpan 1541 May - June 2018


LV Switchgears

JB Switchgear appointed as Blokset partner in South Africa BLOKSET is a benchmark design which has proven itself on thousands of installations worldwide, and is constantly satisfying customers in their search for optimised solutions on their plants, providing reliability and user-friendly installation, operation and long-term maintenance.

LOKSET, Schneider Electric’s IEC 61439-1/2 distribution and motor control switchboard

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LOKSET, Schneider Electric’s IEC 61439-1/2 distribution and motor control switchboard was launched into the South African market in October 2014. In line with its vision for the future, Schneider Electric recently appointed Gauteng-based JB Switchgear as a local licensed and authorised manufacturer of this impressive product.

BLOKSET is a modular system rated for currents up to 7000A/100kA and internal arc 100kA/400mS. It follows global design and is type tested and certified according to IEC 61439-1/2, and IEC/TR 61641, which promotes the safety of both the installation and the operator. BLOKSET is a benchmark design which has proven itself on thousands of installations worldwide, and is constantly satisfying

The team that makes things happen at JB switchgear

May - June 2018

customers in their search for optimised solutions on their plants, providing reliability and user-friendly installation, operation and long-term maintenance. The product offers internal arc mitigation in accordance with IEC/TR 61641, earthquake and seismic activity withstand, as well as superior anti-corrosion properties, making it ideal for a wide variety of industrial sites including mining, paper and pulp, water treatment, cement, automotive and power generation. JB Switchgear fits the requirements of Schneider Electric’s initiatives to stimulate local manufacturing and technology, especially for a high-end product such as this. ‘JB Switchgear has the competence, track record and knowledge of the market that synchronises perfectly with Schneider Electric’s market development strategies going forward’ says James Calmeyer, Vice President – Building Business of Schneider Electric South Africa. Johan Basson, MD of JB Switchgear added that Schneider’s BLOKSET modular system enhances the company’s offer to market with a product that carries impressive technical clout, global respect, and the confidence which comes with an internationally backed and supported product range. ‘JB Switchgear enjoys a strong reputation for quality, innovation and technical integrity, and this appointment will contribute to take us to the next level’. The BLOKSET system will be produced at JB Switchgear’s Brakpan-based factory, which is ISO 9001 listed for quality management. Please contact Johan Basson should you have an enquiry or would like to view the panel at our factory. 21


Machine guidance tools

Guidance for efficient and safe mining Conveniently, integrated machine guidance keeps the equipment connected in real time. Beneficially, it identifies and prevents potentially misdirected loads through seamless integration with various systems.

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achine guidance tools are no longer a luxury they were regarded a few years back. Now, they have become standard in critical operations in exploration and mining due to changing conditions in mining. The cost of running mining operations has skyrocketed due to increase input costs, in addition to regulators’ vigilance on safety. This has prompted mine operators to seek smarter, safer and cost effective technologies of increasing productivity. And machine guidance tools fit the bill. A survey manager at Botswana mining giant, Debswana, could not put it better when he observed about the necessity of machine tools: "The problem facing mining engineers is to maximize the economic benefits of a project without putting the mineworkers and mining equipment at risk.” Machine guidance tools are being used in drill navigation, eliminating errors that surface with conventional drill guiding. Case in point LV board 1 3/22/2018 12:31:31 PM is A classic case of aHpfc.pdf machine guidance tool the ProVision Shovel system, which actively

Every gram of load has to be accounted for and payload monitoring is the only efficient way this can be done

guides operators through a high-precision GPS to dig the correct material. The system keeps the designed bench grade while respecting dig limits, and working within the machine's optimal operating specifications. ProVision Shovel system developer and supplier comments, “The system integrates with mine planning software, providing operators with real-time updates to ore boundaries for improved resource management. The guiding system shows real-time track elevation against plan, helping to reduce bench grade rework and improve drilling performance on subsequent benches.”

System integration It is extremely difficult to supervise several operators in a project. As expected, mistakes, which could have been easily avoided with earlier detection and minor intervention or supervision, occur. Every modern mine has a wide range of equipment such as shovels, dozers, graders and draglines which are required to function together to keep the haul cycle turning, as Devon Wells an expert from OEM, Wencom, comments. Conveniently, integrated machine guidance keeps the equipment connected in real time. Beneficially, it identifies and prevents potentially misdirected loads through seamless integration with various systems.With an integrated system, all plant equipment stays in sync, allowing each unit to work from the same database easily sharing information, this could be shovels or dozers, loaders or light vehicles.

Read More of this article on: http://ambriefonline.com/

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DIESEL ELECTRIC SERVICES MEETS ALL REQUIREMENTS FOR SANS 61439 CERTIFICATION FOR LV SWITCHBOARD DESIGN AND MANUFACTURE

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Diesel Electric Services continues to improve our design and manufacture capability and processes to meet the latest SABS and International Standards. We are proud to announce that we recently met all the requirements for SANS 61439 certification for Low Voltage switchboards. This in addition to our already well known range of LV switchboards complying to SANS 60439 (50kA and 70kA). For more information contact: sales@dieselelectricservices.co.za 22

May - June 2018


IBIS-ArcSAR

All-new innovative slope monitoring radar IBIS-ArcSAR is the first and only radar in the mining industry to provide 360° pit coverage capabilities from one single equipment.

IBIS-ArcSAR is also the first full 3D SAR radar system utilizing the proprietary mimo antenna array and automatic DTM surve

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DS GeoRadar’s unrivalled expertise in innovative slope monitoring radar has once again led to a technological revolution by introducing the next generation radar system based on the ArcSAR technology. IBIS-ArcSAR is designed for fast deployment and robustness to ensure the highest safety standards to manage risk conditions with confidence. Whether it is a strategic or tactical positioning, IBISArcSAR delivers unprecedented flexibility and performance to make critical decisions. IBIS-ArcSAR is the first and only radar in the mining industry to provide 360° pit coverage capabilities from one single equipment. The system leverages the widest and longest range (5,000 meters), and the shortest scan time (360° in 40s; 180° in 20s) as well as built-in

GNSS for auto-geocoding. The outstanding spatial resolution of 10 million pixels sets new standards for critical safety monitoring by covering the full scale of slope instabilities from sub-bench to broad wall movements even at long distances. Quality of data is always guaranteed by IDS GeoRadar’s state-of-the-art atmospheric correction algorithm and smart data management system. IBIS-ArcSAR is also the first full 3D SAR radar system utilizing the proprietary mimo antenna array and automatic DTM survey. The system also features integrated panoramic HD camera providing real time imagery of pit walls and immediate visualization of critical areas. Integrating seamlessly into the Guardian FPM360 suite, IBIS-ArcSAR can

dramatically expand overlap areas of multiple IBIS radars to exploit the unique TrueVector capabilities, delivering a rich geotechnical environment. One solution combines radar data, prism displacement and slow movement analysis into a single versatile platform without the need to invest in additional software. Features: • Scan range: up to 5,000m • Maximum coverage: 360° H x 120° V (70° V per session) • Scan time: 360° in 40s; 180° in 20s • Resolution: 10 million pixels for full resolution scan • Integrated solar panels, diesel generator and optional wind turbine • 3D SAR1 and automatic DTM survey

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• Built-in HD camera on rotating radar head (with link to radar data) • Integrated GNSS • Operates in all weather conditions and temperatures (-20°C/50°C2 to +55°C) • Power consumption: 100W • Fully remote operation (wireless radio link) and optimized file size for low bandwidth • Alarm generation with user-defined levels and multiple alarm criteria • Zero delays in data processing and alarm generation • Exportability of georeferenced output to mine planning software • Built-in geotechnical analysis tools • Integration in FPM360 TrueVector suite 23


Certified Reference Materials

More from ore through matrix matched reliability Encouraged by positive feedback, African Mineral Standards (AMIS) is ready to grow the footprint of its Certified Reference Materials (CRMs) in the African mining sector and beyond.

Client requirements are handled by an organisation with experienced chemists, geologists and scientists who are proficient in what they do

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Exploration and mining companies have become more conscious about the integrity of the data from laboratories that they use to make crucial decisions when implementing their projects. One of tools they are relying upon to determine the accurate composition of ore are Certified Reference Materials (CRM’s). Committed to ensuring that the industry exacts maximum value from their invaluable assets, Raksha Naidoo and Jumien Peceur, two experts from AMIS), are advising exploration and mining companies in Africa 24

and to focus on the quality of the CRMs they use. Raksha Naidoo is the company’s managing director, and Jumien Peceur is the company’s Head of Business Development. Proficiency Naidoo and Peceur are informing organisations about AMIS’ proficiency in addressing complex CRM requirements for clients in diverse mineral commodities. AMIS is a leading international manufacturer and supplier of a wide range of matrix matched Certified Reference Materials (CRM’s).

The company also runs an independent and confidential interlaboratory Proficiency Testing Schemes (PT). In a nutshell, AMIS’ line of business entails: Sales from the AMIS online shop, making CRM's for customers from their own ores, and the AMIS Interlaboratory Testing Scheme. Passion for quality AMIS is very passionate about providing the best CRM’s for a diverse clientele, Peceur explains. “We are committed to assist the mining, exploration and geochemical laboratory

industries around the globe monitor laboratory performance by developing, producing and supplying a range of quality Matrix Reference Materials.” Each of AMIS’ Matrix matched CRM’s is made out of a different ore and characterised for the economic elements, deleterious elements, major and trace elements and specific gravity. The company’s inventory includes a wide range of CRMs covering various commodity types that can be found within the mineral markets. May - June 2018


QUALITY CRMs

FOR MINING AND EXPLORATION

AMIS is an ISO17043 accredited producer of mineral certified reference materials (CRMs). CRMs are used in routine mineral laboratory QA/QC programs, analytical method validation and calibration of analytical equipment. All our products are matrix matched and custom made from naturally occurring materials. In addition we run a free laboratory proficiency testing scheme with its participants being some of the best and well known laboratories in the world. Please have a look at our offerings on the AMIS website, www.amis.co.za and remember there is No Analysis Without An AMIS.

CONTACTS AT AMIS Feel free to contact us if you have any questions or want to discuss our services in more detail. Alternatively, have a look at our website, www.amis.co.za if you would like more information on purchasing or custom making CRMs, or if you want your laboratory to participate in the free AMIS PT scheme.

www.amis.co.za


Certified Reference Materials

Personalised approach What makes the organisation well-equipped to manage contemporary industry requirements is the ability to offer personalised CRM’s for clients, explains Naidoo. “AMIS encourages customized products to all our customers. Our products are matrix matched, thus making them geologically comparable, however it is always best to have a custom made CRM made from your own ore body.” Best practice AMIS’ approach is in line with best practice in assay laboratories, which is to have a custom CRM for every type of sample sent to the assay laboratory, explains Naidoo. “We enable a company to commission 5 to10 (or more) different CRM’s for a single deposit type or even a single mine. These CRM’s will cover different grades, ore types, concentrates, residues and shipping materials.” AMIS provides full and complete

information and data on certificates for both economic and uneconomic trace elements, multiple analytical methods, and individual assay results, on request, if customers wish to do additional stats. Quality assurance AMIS subscribes to the highest possible certification standards. Its CRM’s have been tested by international laboratories and have been validated by an independent geochemist. Furthermore, as an ISO 9001:2008 Certified Producer, the company’s CRM’s are made according to ISO 17034. AMIS is an ISO17043 accredited PT scheme provider, running over 50 PT schemes a year with its global laboratory partners. Track record AMIS has the capability to supply its CRM’s to any part of the world to organisations in diverse sectors. Since inception, AMS has produced hundreds

VITAL ENGINEERING MANUFACTURING QUALITY GRATING, STAIRTREADS, EXPANDED METAL, MESH AND HANDRAIL SYSTEMS SINCE 1939.

of new CRM’s and certified over 500 RM’s and CRM’s for organisations spanning different industries worldwide. Hearteningly, feedback gathered from end-users has demonstrated that AMIS’ Matrix matched CRM’s improve laboratory quality control and lower overall assay costs.

handled by an organisation with experienced chemists, geologists and scientists who are proficient in what they do.” As a final point, Peceur says the AMIS is looking forward to supplying its CRM’s to more clients in Africa and beyond.

Building partnerships Naidoo assures customers worldwide: “We provide outstanding products and problem-solving solutions by building partnerships with our Customers, suppliers and other service providers and maintaining a culture of excellence in customer service. Engaging us guarantees five things for the client: Independent, Unbiased statistics, Ethical practices, Exceptional technical capabilities, and Outstanding service levels.” She adds, “When dealing with us, clients should be assured that their problems are being

" Since inception, AMS has produced hundreds of new CRM’s and certified over 500 RM’s and CRM’s for organisations spanning different industries worldwide."

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grating | expanded metal | handrails | vitagrid | maclock | vitacon | vitex | grating | expanded metal | handrails | vitagrid | maclock | vitacon | vitex

Since 1939 Angus McLeod and Vital Engineering have established a reputation for quality and service in the manufacture of all types of gratings, stairtreads, pressed floors, safety handrails, exapanded metal and solid forged stanchions. Vital Engineering supply a quality product range to the petro-chemical, power generation, mining, processing, food, beverage and other industries, both locally and overseas. Patent no. 90/5955 (other patents pending). Our range is designed in accordance with DIN, BS, NAAMM and ISO standards.

Our unique innovative design has found worldwide acceptance from all industries. Various grades of material and finishes are available, enablingthe client to select one construction type.

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May - June 2018


Mobile communications

6 features miners expect from TETRA radios With recent changes in the market, there is a requirement for mines to improve safety, increase efficiency and operating costs, through among a host of measures, reliable and safe communications between employees.

U

nder the Department of Mineral Resources’ Mine Health and Safety Act (MHSA), mine operators MUST invest in measures that enhance the safety of their employees. One of the essential investments they can make is in efficient communications systems. TETRA is now universally regarded as the benchmark for communications in the mining environment. However, it must be added - only if it meets basic requirements. Specifically, what are they? 1. Crystal clear voice With the never ending purr of machines and blasting activity, miners work in a noisy environment. Therefore, good voice quality is requisite, in addition to the ability to filter background noise. 2. Robustness In the unforgivable environment of tunnels in which they work, miners are exposed to dust,

mud, and extreme temperatures. That is why radios have to be robust enough to withstand these conditions. 3. Quick call for help In the event of a dangerous situation, the red emergency button on the TETRA radio should work effectively and transmit an alert and the radio’s location automatically. 4. Underground radio coverage Through the Direct Mode Operation (DMO) feature, TETRA radios must cover the whole mining area. 5. One-to-one and one-to-many calls TETRA radios should allow for either individual or group calls. By creating the predefined talks groups dynamically, the dispatcher can create the predefined talk groups dynamically over the air during field

May - June 2018

operations. Most importantly, it saves the cost of laying cables. 6. Dispatchers A reliable and flexible connectivity and dispatching solution between the central admin office and remote offices is paramount. The ideal TETRA radios support transportation tracking (AVL) and telemetry applications, which enable efficient fleet management. Suitable for mines With changes in the mining environment, there is a requirement for mines to improve safety, increase efficiency and operating costs, through among other measures, through reliable and safe communication between the employees. And TETRA radios are just what the doctor ordered.

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Robotic cathode stripping technology

Robotic reliability Toronto based, a robotic CSM technology specialist company, EPCM, urges companies in the African metals industry to adopt robotic cathode stripping technology in order to contain costs and improve efficiency. The company is eager to render its expertise to respective countries.

EPCM offers a complete service and supply from installation design to spare parts and maintenance.

I

t is easy to take the benefits of robotic cathode stripping technology in plant modernisation, expansions and development of new refineries, for granted, and forget how far we have come. How did the industry operate without robotic cathode stripping technology? To appreciate the relevance of robotic cathode stripping in contemporary times, one should look at three areas: the phases of development that cathode stripping has undergone over the years; the convenience of robotic cathode stripping; and its scope of applications. African Mining Brief examines these areas as documented by Toronto-based EPCM. Cathode stripping phases of development i. Starter Sheet Technology Prior to the late 1970’s, the primary commercial copper refining method was to electroplate the copper on starter sheets, produced by plating a

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thin copper deposit on titanium “mother blanks” which were stripped off and hung on hanger bars to form a cathode. Although this “Starter Sheet Technology" remains in limited practice today, the introduction of “Permanent Cathodes” manufactured out of stainless steel sheets started around 1978. ii. Permanent cathodes There are two fundamental types of Permanent Cathodes; both use a stainless steel plating surface and a conductive hanger bar. The difference is in the way the side and bottom edges are masked to prevent copper plating in these areas. Originally, wax was used to seal the edgestrips on the vertical edge while the bottom edge was dipped in a wax bath. Wax, as a masking agent, introduced another foreign material into the electrolyte which eventually was replaced with a “Waxless Process” which was commercialised and offered

to the industry in 1992. Today, there are a few plants using the wax technology but they are gradually disappearing. iii. Cathode Stripping Machines (CSM) Simultaneously, with the evolution of the Permanent Cathode development, the technology for “Cathode Stripping Machines (CSM)” for harvesting the copper experienced a similar development phase. First, there were “Linear CSM’s designed to process cathodes with wax. As wax fell out of favour, the linear machines were modified accordingly. The second major CSM was the “Carousel” design where the stripping process functions were arranged on a circular frame and the cathodes were harvested as they rotated through each station. iv. Robotic Based CSM The Linear and Carousel designs started to be replaced by Robotic

Based CSM in 2005. The first fully Robotic CSM was installed for the modernization of a 275,000 tonne per year, starter sheet, refinery which was being converted to Permanent Cathode Technology. The modernisation project was complicated by the necessity to maintain full plant production during the project implementation. Two Robotic CSM systems were ultimately installed, however during the project the plant production was handled by one Robotic CSM. This was possible because of the high efficiency and availability inherent in Robotic CSM’s. Over the last 13 years, the utilisation of Robots in CSM design has expanded and been perfected to the point where it is the preferred option for plant modernization, expansions and new refineries. Any inherent concern about the utilisation of a higher technology has dissipated and robotic material handling is being employed in regions where the technical level of operators and service providers may be less experienced. Robotic Material Handlings Unique Features The use of robots allows all of the normal process functions of a cathode washing and stripping system to be maintained, but has many benefits over conventional carousel and linear systems, including: 1.

High Reliability: Robots for industrial applications were developed in the automotive industry, where high equipment reliability is an absolute requirement. In fact, the robots used in the EPCM stripping systems have a proven history of over 64,000 operating hours between major failures May - June 2018


(MTBF). 2. Flexibility of Operation: The use of robots to handle material between process stations allows flexibility in the operation of the system. For example, the stripping stations are modular, so multiple stations can be used to increase the operating capacity of the system. Additionally, optional stations such as sampling and corrugating can easily be added to an existing system without major changes in plant layout or programming. 3. Flexibility of Installation: Robots allow inherent flexibility in the location of process components so that the system layout can be more readily adjusted to suit the available space in the plant. 4. Lower Noise Levels: The use of robots for product stacking minimizes sheet dropping, which is known to be a source of high noise levels. 5. Lower Installation Cost: The stripping stations are primarily modular and are shipped fully assembled to reduce the installation time and cost in the field. In most installations, a robotic CSM can be installed on a flat floor slab, without requiring extensive pits and machine foundations. This fact significantly reduces the installation cost of the system. 6. Maintainability: The CSM is simpler, more open and accessible for operation and maintenance. There is very little maintenance to be done on the robots which have undergone years of development and manufacturing quality control in order to satisfy the requirements of its end users. 7. High Efficiency: The robots utilise efficient servo motor drives which have greater electrical efficiency than the hydraulic components traditionally used on custom material handling equipment. 8. Production: A robotic

EPCM's robotic CSM technology at work in the Democratic Republic of Congo

CSM has the highest average production rate which has been found to be up to a factor of up to 2 times that achievable with conventional custom machine systems. The adaptability of Robotic CSM systems Robotic CSM systems were originally developed for harvesting copper cathode blanks. Similar designed systems can be adapted for harvesting other base metals and special applications such as: • Cathode product sorting and stacking • Sampling Latest Innovation in Robotic CSM EPCM, a company based in Ontario Canada, has the latest innovations in Robotic CSM. With 26 years of experience, having been established in 1992, EPCM is a leading supplier of Stainless Steel Cathodes and Cathode Stripping Systems for the base metal electro refining and electrowinning industry. Through its development and continuous improvement programs, EPCM has created the following ground-breaking innovations: Robotic material handling, SP Cathode washing, under running transfer car, and Full length edge strip press. The company’s systems have a range of automation levels that vary from 40 to 500 cathodes per hour. Worth mentioning amongst its product range is the SP Cathode Wash System, which has built a reputation for a superior cathode

wash, improved copper quality and a system with excellent access for easy maintenance.

Turnkey CSM package EPCM offers a complete service and supply including: Installation design; CSM machine design; CSM shop assembly; shop testing; on site installation supervision; startup supervision; spare parts and maintenance. For some clients, the company provides daily onsite maintenance, preventative maintenance and plant system upgrades. Companies in various industries now recognize EPCM’s expertise in robotic cathode stripping. Small wonder, since 1992, the company has been involved in hundreds of projects that are too numerous to be documented. In summary, mainly they span the span the following areas: • Technology - Participated in projects today are utilize

May - June 2018

more than 1,000,000 cathodes and which produce over five million tonnes of copper annually. • Engineering - EPCM has provided engineering services and technology to the base metals industry for over three decades Potential for robotic CSM in Africa EPCM views the African metals industry, in which some companies have clung onto time-consuming and onerous cathode stripping technology, as a potential market for robotic CSM technology. With its wherewithal, the company is eager to provide solutions that will help companies to contain costs and improve efficiency in their refineries.

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SP Robotic CSM*

SP

TANKHOUSE TECHNOLOGY


EPCM is a leading supplier of Stainless Steel Cathodes and Cathode Stripping Systems for the base metal electro-refining and electrowinning industry. Our systems have a range of automation levels that vary from 40 to 500 cathodes per hour. Since 1992, EPCM has been involved in projects that are utilizing more than 1,000,000 cathodes and which produce over five million tonnes of copper annually. Our development and continuous improvement programs have created innovations which are a major benefit to copper producers around the world. Some of the innovation highlights are: • Robotic material handling • SP Cathode washing • Under running transfer car • Full length “edgestrip” press

Superior Performance (SP) EPCM cathode washing and stripping systems utilize robotic technology for material handling. The benefits of robotics over conventional carousel and linear conveyor systems are: Reliability EPCM introduced this standard to the world tankhouses by pioneering the Robotic CSM. The robots used in the EPCM stripping systems have a history of over 64,000 operating hours between major failures (MTBF). Flexibility The use of robots increases operating and layout flexibility. Noise Reduction Robot product stacking eliminates the noise generated by traditional sheet stackers. Lower Capital Cost A robotic stripping system can be installed on a flat floor slab. Improved Maintainability Better equipment installation for easier maintenance. Energy Efficient Robots utilize servo motor drives. Higher Productivity Reduced operator intervention stoppage.

Your Winning Solution

* Patent pending

EPCM Services Ltd. 2829 Sherwood Heights Drive, Oakville, Ontario, L6J 7R7 Canada

Tel : 1.905.829.1711 Fax : 1.905.829.1717 www.epcm.com

• • •

oakville@epcm.com giverson@epcm.com gerardf@epcm.com


Electrowinning

The pursuit of energy-efficient extraction The trickiest part of a copper-cathode electrowinning plant is creating the perfect conditions to extract more ore with low energy consumption.

A

s documented in other sections in this publication, in pursuit of getting more value from ore with as minimal capital expenditure as possible, electrowinning plants for copper-cathode production have become an area of interest in mining. There is more focus on how this very important equipment can be made to work optimally. The emphasis on electrowinning should not be surprising at all. MPPI global, an independent mining improvement company, estimates that electrowinning plants produce in the region of 20% of global copper production. This demonstrates the confidence that the industry has in electrowinning as a reliable method. Preferred method Compared with other methods, electrowinning is preferred for producing quality copper Busbar Tpfc.pdf 3/7/2018 4:49:37 PM cathode, with low 1energy consumption and high current efficiency. However, this

is only attainable under one condition: keeping the electrowinning section running at the maximum rate while understanding the effects and interaction between common chemical and physical parameters affecting the production of copper. Common obstacles More often than not, there are a number of obstacles that operators encounter in the course of operating their plants. In a commentary, MPPI global says it has noticed that issues that commonly surface are a lack of visibility and understanding, poor monitoring and control of copper concentration, iron concentration, manganese content, cobalt concentration, acid concentration, electrolyte temperature, solids in solution and cell flow to name a few. Over and above these, there are physical plant issues such as anode and cathode maintenance and quality, anode and cathode cell alignment, shorts detection and

correction, current density, corrosion, poor stripping strategies, and reliability issues at the crane and stripping machine. With the aforementioned factors, MPPI global admits that it is not always easy to achieve stability, efficient production and optimisation can be difficult to manage with so many influencing factors. Process control and automated monitoring systems Progressively, process control and automated monitoring systems are improving productivity and minimising energy consumption in electrowinning plants. Systems for wireless, online individual cell measurements of temperature, voltage, and current have found application in industry. One of the revolutionary technologies is Hatch’s HELM Tracker™ technology, which tracks and trends real-time current in individual electrodes. South African consulting firm, Sole Consulting, which has highlighted the above developments in a review, predicts that increased scrutiny and attention will lead to greater automation and better control and monitoring.

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M

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CM

MY

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CMY

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May - June 2018


Cathode edge strips

Extending cathode uptime Consistently monitoring cathode straightness and edge strip condition allows for timely intervention. Thankfully, new technology has simplified this task.

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ining and mineral processing companies are leaving no stone unturned in their quest to increase efficiency from mine to mill while keeping operating costs manageable. Noticeably, one of the areas that they have targeted is electrowinning tankhouses. Plausibly, persistent problems with permanent cathodes have a direct impact on tankhouse performance. These can be addressed through good maintenance practice. In accordance with standard practice, cathode maintenance entails regular checking and replacing edge strips, followed by cathode straightening and cleaning of residual copper deposits. More often than not, the problem is with worn-out edge strips. Jukka Tähkä, Manager at Boliden Harjavalta's copper refinery in Finland, stresses the importance of best practice in cathode maintenance: “It is a huge mistake to think of a permanent cathode as merely a simple steel plate. In fact, cathode performance is essential for the refinery’s profitability. Its straightness has to be just right; otherwise copper production is not optimal but energy costs stay. Also, it goes without saying that the cathode’s most important feature, the edge strip, needs constant attention.”

Edge strips critical Located on the vertical sides of the cathode blade, edge strips are critical to permanent cathodes of all designs. The edge strips prevent deposited metal from growing around the cathode and allow the cathode deposit to be removed in the stripping machine. L. Nordlund and H.Virtanen from Outotec (Finland) have compiled information on the subject in review, Development of permanent cathode technology and related lifecycle solutions, which was presented at SAIMM event in Johannesburg. The two demonstrate why edge strips are essential: “During the metal stripping process, the edge strips are subjected to mechanical forces tend to move or damage the edge strip. When this process is carried out repeatedly, electrolyte eventually penetrates between the edge strip and cathode plate surface causing damage to the edge strip that gradually becomes worse.” The two acknowledge that tendency of edge

strips to wear out prematurely has been a topic for discussion since the introduction of permanent cathode technology. Frequent edge strip replacement causes downtime and is very costly as it involves replacement expenditure. Usually, Nordlund and Virtanen state, the life of an edge strips averages 1 to 2 years. They reveal that new advances from Outotec have increased the life of edge strips to more than four years of service interval per cathode. Automated cathode maintenance Outotec's edge strip technology withstands the high stress and impact caused by mechanical stripping. a seamless attachment to the plate prevents copper from growing around and under the edge strip, thus extending the maintenance interval – and eventually the lifespan of the entire cathode. Outetec’s automation system eliminates the shortcomings of human involvement in cathode maintenance. A machine vision detects the cathode’s edge strip and straightness and based on pre-defined tolerance levels, directs cathodes either back to production or for maintenance and to the stripping machine’s reject conveyor.

May - June 2018

We are a South African Manufacturer and supplier of plastic Cathode Edge Strip systems as well as related Anode Insulation products. Included are solid Cone and Star type buttons and Diamond side insulators for use in the electro-winning of Copper and Cobalt in mining processing plants.

Email Mobile Tel/Fax

roland@corrosionservices.co.za bridget@corrosionservices.co.za +27 (0) 83 263 2939 +27 (0) 84 555 6731 +27 (0) 11 425 1599

9 Hills Street, Rynfield, Benoni, 1501

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Corrosion protection in a package

VCI power Volatile Corrosion Inhibitors (VCIs), sometimes referred to as vapor corrosion inhibitors, packaging has been endorsed globally as an effective alternative to conventional method of corrosion and rust protection of valuable, but vulnerable metal parts.

W

hen it comes to corrosion protection for metal parts that are to be stored or transported, the first thing that springs to mind is the conventional approach of corrosion protection like using wax or oil. Nonetheless, the limitations of these methods have been extensively chronicled. For instance, with traditional methods, metal parts are often dipped in petroleum-based rust preventatives that require cleaning and proper disposal before use of the part. In addition, these methods fall short when exposed to extreme humid conditions. Volatile Corrosion Inhibitors (VCIs), sometimes referred to as vapor corrosion inhibitors) packaging has been endorsed globally as an effective alternative to conventional method of corrosion and rust protection of valuable, but vulnerable metal parts. A compound of environmentally friendly corrosion inhibitor chemicals, VCI are introduced into plastic bags or film, and paper at the point of manufacture. VCIs ensure that the parts are in pristine condition, protected from extreme environmental conditions and humidity changes better. The magnitude of the problem To appreciate the relevance of VCI packaging better, one has to look at the magnitude of the problem of corrosion in industries. Relating to the subject, US-based Green Packaging Inc. makes interesting observations regarding corrosion: it is only through understands how corrosion occurs that companies can seek effective solutions on how to control it. The following are the observations that the company has made about corrosion: • The corrosion reaction between metals and oxygen is immediate and continuous unless the corrosion cell perpetuating the reaction is stopped • Corrosion on metal is a result of oxidation – a molecular, destructive reaction between oxygen and a metal’s surface • While some would argue that oxidation does not weaken metal, its surface

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disintegrates, a brittle films forms. However, rust does weaken metal and is a serious concern. The suitability of VCI VCI packaging creates an invisible molecular layer of corrosion protection on metal surface, according to Green Packaging’s explanation. Routinely, the corrosioninhibiting compound migrates from the VCI packaging – this could be paper, poly bag and foam emitter – into the packaging environment, while a thin layer of protection adheres to metal surfaces, reaching into recessed areas, hooks, nooks and crannies. VCI packaging adjusts to the temperature and humidity for efficient protection. Also, vapours replenish inside the contained package. Then, the inhibitor forms a barrier between the metal surface and moisture in the atmosphere, thereby preventing corrosion. Case in point A case in point of how packaging materials protect metal goods from corrosion include is Cortec Corporation’s Vapor phase Corrosion Inhibiting (VpCI) Technology, which is used to safeguard metal components during shipment, when extreme humidity changes can put metals at risk for corrosion. Typically, VpCI molecules incorporated into a packaging material work by evaporating into the air and forming a protective molecular layer on all metal surfaces inside an enclosed package. When the component reaches its destination, it can be unwrapped and used immediately without additional cleaning or degreasing. Massive benefits VCI offer massive benefits compared with traditional corrosion protection methods. The main ones are reduced downtime, environmentally friendly, and improved protection of metal components. • No downtime due to part wear With VCI equipment does not experience

downtime as a result of wear of parts due to corrosion, which can translate into loss of potential revenue. If it is coatings that are used in corrosion protection, there is additional cost in terms of surface preparation and coating reapplication. • Environmentally friendly VCIs are a recyclable alternative to polyethylene and waved papers. They are non-toxic, fully repulpable and recyclable. Different specifications for different sizes All in all, it is important for companies to make informed choices when selecting VCIs for their respective requirements. Naturally, one cannot use the same specification for different metal parts. The rule of the thumb is that, since metal parts are manufactured in different sizes, weights and shapes, they require different corrosion-inhibiting packaging solutions.

Baypac (Pty) Ltd – specialists in volatile corrosion inhibitors Baypac (Pty) Ltd specialises in Corrosion Protection and offers both Corrosion Protection Packaging in the form of VCI (volatile corrosion inhibitor) bags, film and paper – and a comprehensive range of Corrosion Protection fluids from Avia Bantleon. The company has representation in all of the provinces in South Africa and is available for consultation regarding any corrosion problem you may have. So whether you need long term rust free storage without the use of oils and waxes, or you need to protect the inside of a gear box or tank, the company is able to provide tested and proven solutions for your requirements. May - June 2018


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Payload monitoring

Loading efficiency through intelligent monitoring Traditionally, payload accuracy has been highly dependent on the skill and competence of the individual operator in control of each machine, with inherent human error in operations. Indisputably, the impact of payload monitoring has been revolutionary, Writes MATIMU MAHUNDLA.

T

he loading cycle in a mining operation is another critical stage in the production process that requires efficient monitoring to optimise performance. This is depends on timely, accurate and clear data to assist in ensuring consistent loading practices. Ideally, each truckload should have an ideal target weight that minimises cost and maximizes profit. However, loading practices can result in dramatic variance in shoveltruck productivity between different operators due to loading practices. Inconsistent truck loading can impact significantly on mines productivity and profitability. A specialist in load monitoring systems, MineWare founder and chief executive officer, Andrew Jessett, observes that consistent under loading of five trucks in an operation by just 20%, is equivalent to under-utilising one whole truck, which is a gross loss to an operation. On the one hand, when a truck is constantly overloaded, components lifespan decreases significantly, for instance, premature tire wear or even suspension failures. On the other, when a truck is under loaded, more trips and passes are needed to transport the same amount of material. Inconsistent truck operations can also result in truck bunching, material spillage, high energy consumption, all resulting in both operational and maintenance costs. Without doubt, efficient monitoring systems that provide relevant stakeholders with accurate data to adjust the loading processes immediately when non-target payloads are identified are a necessity. Specifically, operations should 36

Efficient monitoring systems that provide relevant stakeholders with accurate data are a necessity

be boosted with systems that provide accurate payload measurements, coupled with efficiencies that allow operators to optimise their loading processes. Mike Jackson, the Director of International Business Development at Ramjek Technology Solutions, has been raising awareness about the importance of effective payload monitoring in mining operations in current mining conditions. He states, “The ability to monitor payload in real-time, provides the operator of the loading unit (face shovel / backhoe / frontend loader) with actionable information to guide decisionmaking during the loading process. This allows adjustments to be made bucket-by-bucket while the truck is being loaded, ultimately guaranteeing the ‘right-loading’ of trucks (i.e. trucks loaded accurately to their rated payload).” Optimising loading and haulage operations The tools for optimising load efficient are readily available and the onus is upon mine operators to make decisions. Companies

are producing intelligent monitoring systems of loading cycles that increase productivity through reducing and avoiding delay times during the production process. Extraordinarily, there are devices that continuously monitor the various activities of the equipment, recording data of all the vital signs and storing them in a database. The systems use a series of orientation and pressure sensors to provide bucket-by-bucket payload measurements to ensure every bucket and truck box fill is optimised. With the recorded data, the status of equipment performance can be displayed either in real time or at the end of the shift. In any case, the loading planning can be tracked and the management of the cycle can be improved. Researchers from the University of Toronto, Vasquez Coronado and Pedro Pablo, encapsulate the wonders of payload monitoring that. They comment, “Technological equipment for monitoring, ultimately optimising haulage cycle provide real time data on how much ore or waste is required to be transported along

a path in the network of haul roads in order to manage the loading work. “In addition, it focuses on how operational trucks have to be assigned to shovels for the system to be efficient, and how many trucks need to be used for achieving the production objectives. “The method helps supervisors to understand the loading requirements and the transport and hauling activities have to deal with, with its respective solutions, which serve as a baseline for finding the source of such problems,” say the researchers. Concurring with their view on efficiency, Jackson says that installing a digger-based, realtime payload monitoring system increases production between 3% and 16%. This equates to a return on investment for most mines in under six months. “Without a system in-place, shovel operators are “working blind”, guessing at the payload they are loading into the trucks. Only after they’ve loaded the truck do they then get feedback on their performance. With a real-time system installed on the digger, the shovel operator gets actionable information, in real-time, enabling important adjustments to be made during the loading process,” says Jackson. Eliminating individual errors Traditionally, payload accuracy has been highly dependent on the skill and competence of the individual operator in control of each machine. Nonetheless, with inherent human error in operations, indisputably, the impact of payload monitoring has been revolutionary. May - June 2018


Machinery CAS

Eliminating Underground Collisions with a Proximity Awareness System

The best way to manage and reduce collision risk in a modern mine is to make use of a proximity monitoring and collision awareness system

The Situation On a typical day in an underground hard rock mine, multiple vehicles, ranging from scoops, trucks and drills to light vehicles and ATVs, move around the mine. At the same time, and in the same space, mine personnel need to get on with doing their work effectively – and safely. Under these circumstances, the risk of vehicle-to-vehicle or vehicle-to-person collisions is high. The large blind spots that operators of LHDs and other large mine vehicles must contend with, coupled with the limited visibility environment, further complicates the task. The Solution The best way to manage and reduce collision risk in a modern mine is to make use of a proximity monitoring and collision awareness system that tracks the proximity of vehicles to workers and other vehicles and warns the operator of potential collision risks. Knowing that there are other vehicles or mine workers nearby, especially when they are obscured by a blind spot, dust, poor lighting etc. or are simply out of the line of sight (e.g. around a corner that is being approached), helps the operator to take appropriate action and massively reduce collision risk. The Technology Newtrax Technologies Inc. has solved the most difficult challenges with the design and

implementation of proximity monitoring and collision awareness systems by working in collaboration with hard rock miners to create MineProx™. Developed specifically for use in underground hard rock mines, MineProx does not rely on the presence of an existing communications network and its advanced filtering capabilties ensures nuisance alarms and false-positives are minimized. Each enabled cap lamp and every equipped mobile vehicle – directly and constantly – notifies all vehicles nearby of its presence, ensuring equipment operators are always aware of nearby hazards. It is ideal for use throughout an underground hard rock mine, functioning normally even if the mine’s communications/data networks fail or are unavailable. Combined with the Newtrax ‘right of way’ application, MineProx can also be used for underground traffic management to ensure operators are kept informed of vehicle prioirities when they approach – making MineProx an effective production and safety management tool. MineProx is proudly represented in Africa by Ramjack Technology Solutions, a leading supplier of underground safety, productivity, and sensor monitoring products and solutions from industry leading technology manufacturers, e.g. Newtrax, Mine Design Technologies, Conspec Controls, uGPS Rapid Mapper™, x-GLO, and SmartCap.

May - June 2018

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Power plant retrofitting

Boosting aging power plants As the continent is engrossed in the euphoria of renewable power generation, it would be remiss for power utilities to neglect the urgency of retrofitting aging power plants. The viability of refurbishment Two specialists, Dr. Klaus-Dieter Tigges of Babcock Borsig Steinmüller, and Mohamed Khan of Steinmüller Africa, have compiled a review establishing the viability of power plant retrofitting in Africa. The two posit that, based on experience, refurbishment and life time extension of existing plants is a good economical approach to assure generation capacity. They say, very often, this can be accompanied by a capacity increase through new technologies. “New capacity of a refurbished power plant is cheaper than a new build. In addition, the projects are implemented in a shorter time with minimal project risks,” Tigges and Khan assert.

Refurbishment and life time extension of existing plants is a good economical approach to assure generation capacity

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f one is privileged to attend one of the growing number of conferences themed around investment in Africa’s power sector, what becomes conspicuous is that renewables are being punted as the panacea to Africa’s power supply shortfall. Unwittingly, what is ignored, as countries are immersed in the renewables euphoria, is the urgent need for investment in the aging power infrastructure, which, currently, is the main source of electricity. According to analysts, the refurbishment of operating power plants to increase generating output can be executed at a comparatively cheaper cost. So, isn’t it about time governments review their priorities in power generation? Or at least maintaining a healthy balance between managing existing power plants and new projects? In a bid to establish how the neglected practice of power plant rehabilitation can be revived, African Mining Brief analyses the current state of the existing power plants, the downside of the bias on capital intensive Greenfield projects, and the appropriate approach to retrofitting power plants. Current state of power plants In an article he wrote for the 2015 World Economic Forum, Klaus Findt, Chief Operating Officer of the KPMG Global Infrastructure and Projects Group in Africa, mentions a number of challenges that slowdown the performance of power plants. The challenges include underutilisation of generation capacity due to low maintenance

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of assets, high operational inefficiencies, ineffective transmission infrastructure and high transmission losses of up to 25%, poor planning, and low skills levels and management capacity. Most perturbing about the situation is that most of problems that speed up power plant deterioration can be forestalled, with the right intervention. Granted, it is inevitable for low performance to be experienced in power plants at some point, but in some cases it happens faster than envisaged. Greenfield constraints Findt captures the magnitude of the challenges that African countries face when undertaking new investments in power generation. Writing on the subject, he notes, “It is estimated that $300 billion will be needed for all of sub-Saharan Africa to have access to electricity in the next 15 years. Currently, we are at 25% which, if you consider consumption per capita, equates to one-sixth of the world’s average.” Worse still, for all the potential they have, most African countries cannot attract investors as they are plagued by inadequate governance, due to a distinct lack of policies, regulatory frameworks in the energy sector, and a lack of independent regulators. Evidently, it is better to manage the proverbial bird in hand that is aging power stations than chase the illusion of the Promised Land of power supply sufficiency that greenfield projects present.

Main objective The main objective of a power plant refurbishment project is improving the performance of the firing system. A refurbishment aims at improving reliability of a power plant which depends very much on the performance of the firing system. Burners play a key role as they determine the requirements on furnace design and coal preparation, Tigges and Khan says. “There is a link between the reliability of a coal-fired steam generator with the performance of the burners. State-of-the art burners feature perfect flame stability and as a result allow a low burner part load.” Using state-ofthe-art burners offers a good potential for performance improvements due to their flame stability and low sensitivity to changing coal properties, Tigges and Khan suggest. “Very often boiler operation is affected by deteriorating coal properties making it very difficult to keep the units online and provide the required generation capacity,” they point out. “If burner modernisation is combined with an improvement of the entire coal handling and preparation system all prerequisites are on hand to get a reliable operation independent of coal properties.” Prior assessment It is worth mentioning that there is no general rehabilitation approach for every power plant, since each site has unique conditions and constraints. For this reason, Tigges and Khan say, the perfect set of measures is determined by an analysis of existing problems and a compromise with regard to budget and allowable outage time.

Read More of this article on: http://ambriefonline.com/ May - June 2018


Web-based exploration information management EDM Tpfc Advert.pdf 1 4/10/2018 8:01:34 PM

Valuable exploration data at the finger tips Relevant, timely, visual, and authenticated information is critical at all phases of the exploration, development and mining life cycle. Conveniently, web-based information management systems provide access to authenticated project information including different data formats, file types and coordinate systems to all the project team members at one central point.

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The accuracy of the information about a site has a bearing on decisions that are made.

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ame changing has become a cliché that is being bandied about liberally, but there is no questioning the impact that web-based data gathering is having on data management in complex exploration tasks. Without good data husbandry, exploration tasks would be a vain exercise - a waste of time and a strain on financial resources. Traditionally, exploration information has been stored in dedicated rooms under lock and key. Piles and piles of files stacked to the rafters end to end. Project reports and drill logs. But no matter how seemingly safeguarded the information is, there is always room for gaps, duplication and inconsistency. Already, this in itself raises questions about the reliability about the information collated. Mapping IT, a firm that offers exploration and mining data management systems provider, offers a candid assesement of the situation: “This is a reality of exploration and mining today. Geo-scientists, engineers and project managers spend too much time acquiring, massaging and managing data and have little time to assess, integrate and interpret the results. With few people and more data, this issue is getting worse not better. A solution is needed where data management is simultaneously transparent (accessible) and invisible (authenticated) so that these professionals can focus on their jobs (application).”

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With a new data management systems gaining traction, it wouldn’t be an exaggeration to say that exploration and mining companies would have to find alternative uses for their store rooms. Handily, invaluable geophysical data can be uploaded on a central secure geospatial server which gives everyone access to catalogue and manage exploration results from QA/QC analysis, 3-D modelling and visualisation. MY

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Gaps While continuous advances data analysis software packages have significantly alleviated some of the data management challenges, a gap persists. As Geosoft alludes in a review which African Mining Brief accessed, some of these challenges can be expensive and complicated, requiring expert technicians to operate. “Affordable, efficient and accurate mining data management remains an elusive target,” says the company. Integration eases the burden Handily, new systems integrate authenticated data, providing easy navigation of information and the convenience of access for key stakeholders for timely analysis. It is not an exaggeration that this has development has revolutionised the management of exploration data. More is yet to come in the words of Canadian geophysicst, Peter Dueck.

May - June 2018

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Rolling stock leasing

Gaining traction

Hearteningly, interest in leasing rolling stock is growing among freight owners in the mining, oil and agriculture sectors, and from concession holders and national railway operators. Transnet’s recent delivery of rolling stock to neighbouring countries is proof positive of this development.

Tansnet's Rolling stock

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he leasing of rolling stock in Africa has been punted as the most viable way to address the problem of underinvestment in locomotives and wagons, which has led to deterioration and depletion of rolling stock fleets on the continent. There is a strong conviction that adopting the leasing model would offer greater flexibility and stimulate the sector. International trend The international trend is moving away from outright purchase of rolling stock to leasing. Typically, Ronnie Ntuli, according to Chief Executive Office and Founder of Thelo Rolling Stock, the leasing option appeals to rail operators that do not have capital available to buy fleets, those that wish to keep these assets off their balance sheets, and those whose businesses are not geared towards being rail asset owners. Generally, leasing rolling stock offers is more cost effective than purchasing locomotives and wagons themselves. Moreover, greater flexibility of leasing is that lessors offer shorter leases 40

and give users options to buy locomotives after a certain period.

rolling stock between different countries increases the residual risk, he spelled out.

Obstacles in Africa Leasing stock is an entirely new territory in Africa, and understandably there is need for more effort to raise awareness. There are two main obstacles to the growth of the rolling stock market in Africa have been cited: skepticism, which is more of a mindset issue than anything, and lack of supporting infrastructure.

• Lack of infrastructure Another reality that has also been repeatedly mentioned during recent discussion revolving around the revitalisation of railway transportation sector is the need to develop rail infrastructure in Africa, where the transportation of goods is difficult and costly affair. Gumede also touched on this. “There are many opportunities for rail within the mining industry in Africa. Commodities have to be transported from the mine to port, but there is a lack of rail infrastructure in many African countries, and therefore they have to be transported via roads, which is not cost efficient.” However, another view on the matter, held by Ntuli, is that there is already a lot of railway track (in sub-Saharan Africa), but the issue is under-investment in above-rail assets.

• Skepticism Understandably, as a concept that is in its infancy in Africa, there is still skepticism about leasing rolling stock in Africa. Two of the main factors behind the skepticism have been cited as lack of understanding of the concept and residual risk. Gumede, then a representative of DCD, a locomotive and wagon manufacturing company, singled out these during a panel discussion during a discussion that was part of the Africa Rail Conference and Exhibition which African Mining Brief attended. For leasing companies, the lack of interoperability of

• Growing interest Encouragingly, interest in rolling stock is growing among freight owners in the mining, oil and

agriculture sectors, and from concession holders and national railway operators. Transnet’s recent delivery of rolling stock to neighbouring countries is proof positive of this development. Transnet, through its newly created arm, Transnet International Holdings (TIH), las month handed mainline locomotives, wagons and passenger coaches to National Railways of Zimbabwe (NRZ) in a transaction valued at more than $180 million, following a public tender by NRZ for its recapitalisation. It is a 25 year concession. The deal will be concluded by the end of July. In Zambia, TIH is part of the revitalisation of the Zambian Railways Limited. This entails leasing locomotives and wagons to Zambia Railways in order to boost its capacity to handle bulk cargo. This is expected to cost in the region of about $8 million dollars. According to Transnet, the revitalisation is expected to cost approximately $8 m. Currently, the infrastructure is in bad shape. Indeed, exciting times lie ahead as locomotives leasing gains traction. May - June 2018


Site-based medical care for Mining, Energy and Infrastructure

Tackling trauma trouble preemptively Dr. Vernon Wessels, a veteran medical doctor for Site Based Medical Services at ER 24, provides African Mining Brief with an insight on highlights of the contemporary state of Emergency Medical Care (EMC) services, how mine operators can address potentially costly oversights, and impact of the slowdown on how mines approach EMC. In addition, there is clinical oversight and consultancy available to crews, as well as formal and informal training options ranging from first aid for the mine employees to professional training courses for the emergency care staff. Medical risk assessments can also be performed, along with assistance with procurement of emergency equipment and consumables.

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t is not easy to gauge the commitment of mine operators to compliance with worker safety in South Africa, through amongst other requirements, the provision of Emergency Medical Care Services on-site. Nevertheless, what is evident is that the Department of Minerals and Resources’ approach has significantly resulted in a mindset shift. Markedly, the Department is very strict on enforcement of worker safety and does not hesitate to shut down operations in the event of a fatality or serious injury if there is concern regarding safety. Fortunately, many mines do have a proactive approach and ensure that Emergency Medical Care services are available onsite and that proactive deployment of resources occurs during potentially dangerous operations, according to Dr. Vernon Wessels, a veteran medical doctor for Site Based Medical Services at ER 24. However, this does not apply across the board and smaller operators are still dependent on external response (other than first aid) in the event of an accident, he acknowledges. So, what is the impact of lapses on operations? What could be the practical approach? Has the economic slowdown affected how mines approach Emergency Medical

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Services? Dr. Wessels addresses each of these questions. Impact of lapses There is no question that inadequate emergency medical care solutions can greatly affect mining operations, states Dr. Wessels, citing trauma as a case in point. “In trauma, time is the most critical factor in many injuries that can affect the outcome of the injured employee. Control of bleeding, re-establishment of perfusion to areas that have had blood supply compromised and proper management of head injuries are a few examples of where proper management can make a difference, whether the patient survives or not, or will be able to have a functional life after the incident. However, inappropriate care and preventable loss of life or functionality can negatively impact on the workforce which can lead to unproductivity and even labour unrest. The duty of care that falls on the employer can also expose them to possible civil and criminal legal action.” Relevance of specialised Emergency Medical Services To manage traumas effectively, an emergency medical services team with skills and experience within the mining sector is highly recommended, says Dr. Wessels.

“The emergency medical services team can assist a mine not only in providing adequate response in the event of an incident but also ensure that proactive measures are in place,” he explains. “Furthermore, it can assist the HSE representatives with identifying risks that can be mitigated or corrected, above and beyond, preparing first responders to be able to stabilise an injured person until the service can reach the patient.” Most importantly, Dr. Wessels emphasises, “Although first aid training is provided to the workforce, regular refreshing of their knowledge during toolbox talks and health talks helps to keep them more alert.” The scope of site-based emergency medical care The scope of site-based emergency medical care provided varies, depending on the type and scale of the mine. In some cases, all that is required is a single advanced life support practitioner to augment an existing in-house emergency response team. In others, the full scope of emergency care from Basic Life Support to Advanced Life Support is provided including crewed ambulances, primary response vehicles, rescue services and offsite aeromedical response and transport.

Mapping out a unique solution Every mine is unique, and so are the potential emergency medical challenges faced. Consequently, Dr. Wessels advises, vital steps have to be followed to address a mine’s emergency medical care requirements when consulted to map up a solution. “The first step is to perform a medical risk assessment which will highlight the potential risks, the workforce demographic, the available infrastructure and surrounding medical resources (hospitals and external emergency medical services) and environmental factors that could affect the workforce and the response to emergencies. Based on this assessment, a client specific solution is proposed which is then adjusted with the client to satisfy their need.” Impact of economic slowdown A recent development that cannot be ignored is the slowdown in the global commodities market, which has resulted in the reduction of revenue in the mining sector. This has prompted mines to optimise efficiency in order to survive, observes Dr. Wessels, pointing out that emergency medical services, which are viewed as a non-core function within a mine, can be targeted for down scaling.

Read More of this article on: http://ambriefonline.com/ May - June 2018


Roll-Over Protective Structure canopies

Stringent testing for superior product integrity ROPS structures were introduced to mining vehicles in the South African mining sector in 2007. Now every mine operator has installed them on their vehicles. Given that they serve a critical function of saving lives in the event of an accident, they are designed, produced and tested under very stringent standards.

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he South African Mine Health and Safety Act 29 of 1996 and Regulations (as amended), in South Africa, or the relevant laws and regulations applicable in other countries obliges organisations to enhance safety at all costs. One of the essential provisions is the use of Roll-Over Protection Structure (ROPS) canopies that provide basic rollover protection for mobile equipment operators that operate in the surface mining and related sectors. Though ROPS vary from vehicle to vehicle, they operate on the same principle. In its manual on ROPS, Anglo American encapsulates what ROPS constitute and entail. Rollover Protective Structures can be defined as a system of structural members arranged on a vehicle in such a way as to accomplish the purpose of reducing the possibility of an operator or

passenger being crushed, when wearing a seatbelt, should the vehicle roll over. This system may form an integral part of the vehicle body, structure or canopy, or may be an additional structural system with such primary purpose. Structural members include any sub frame, bracket, mounting, socket, bolt, pin suspension, or flexible shock absorber used to secure the system to the vehicle frame. Mining groups require FRCP (Fatal Risk Control Protocol) to their vehicles, of which the ROPS/FOPS (Falling Objects Protection Systems) form an integral part of. Compliance standards It is stipulated that all equipment comply with the relevant requirements of the South African Mine Health and Safety Act 29 of 1996 and Regulations (as amended), in South Africa, or

Roll-Over Protective Stuctures for rugged requirements

the relevant laws and regulations applicable in other countries which include: ISO 3471 – 1994 , ISO 3449 – 1992 , ISO 6683 1992 , and SANS 1563 – 1992. Certification in design and production phases It is recommended that All ROPS or FOPS be certified at both the design and production stages. Design certification should include testing of a prototype and/or design verification by a professional engineer in terms of the prescribed requirements. Certification after production of each item of the same design should also be performed. The production certification should be based on a Quality Assurance Plan required by the contract and approved by the company. Maintenance and repair Inspection schedules, which are included in the vehicle

maintenance plans required by the Contract and supplied by the OEM, are a must on all certified ROPS and FOPS. These schedules cover regular checking of welding, fasteners and for structural damage. In case of damage, it is recommended that the OEM or competent repairer to provide a repair procedure on a caseby-case basis, that would ensure that the structure is repaired to its original design, or state that the structure is not repairable. Durability Given that ROPS are used in a critical task, durability of equipment is requisite. One of the standard measures employed is hot dipping ROPS structures to offer protection against rust and corrosion.

EMERGENCY SITE-BASED SERVICES ON CALL By providing dedicated on-site expert emergency medical assistance, ER24 Site Based Medical Services is ready to assist with any medical emergencies on any mine site. We assist to mitigate on-site accident risk, minimising health and safety impacts, therefore ensuring continued productivity across all site operations.

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For more information, please visit www.er24.co.za

May - June 2018

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Hydrogen gas detection

Mitigating hydrogen hazards through accurate detection "Pretoria-based RTS Africa Engineering is specialised company that offers globally-sourced, quality products such as continuous belt weighers without load cells, laser-based gas detection devices for hot or corrosive areas and electrolysers for hydrogen production."

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aid in hydrogen gas detection within battery charging stations in underground mines”, he says. A versatile and explosionproof hand-held hydrogen leak detection device, the Hy-Alerta 500 instrument can detect the widest range of hydrogen gas concentrations without the need for peripheral equipment. In actual fact, the Hy-Alerta 500 can detect hydrogen leaks as low as 15 parts per million and will not saturate or be destroyed when exposed to high hydrogen concentrations up to 100%.

TS Engineering Africa is aware that embarking on the task of adequately equipping as many mines as possible with the capability to mitigate the risk of potential hydrogen gas combustion is a journey of a thousand miles. However, simultaneously, the company is taking big bold steps by raising awareness about the potential safety hazards of hydrogen in mines, as well as introducing solutions to manage the problem. Specialised company Pretoria-based RTS Africa Engineering is a specialised company which was established over two decades ago, to solve some of industry’s toughest challenges. That being said, RTS Africa offers globally-sourced, quality products such as spin filters, laser-based gas detection solutions , as well aselectrolysers for hydrogen production. RTS Africa services a vast array of clientele in sectors such as mining, petrochemical, steel and energy. The company’s highly-trained team provides product delivery and technical consultation throughout Southern and panAfrica. Ian Fraser, the managing director of RTS Engineering Africa, tells African Mining Brief about the scale of the risk of hydrogen combustion within the mining environment, and outlines solutions that RTS Africa can provide. He fears that mine operators either could be underestimating or are unaware of their level of vulnerability to hydrogen combustion. The potential safety risks in underground charging bays The increasing usage of battery-powered electric vehicles in underground mines presents an inherent risk, Fraser explains. “Battery-powered electric vehicles were introduced to eliminate air pollution associated with diesel exhaust emissions.

Hy-Alerta 500

Ironically, this has resulted in an unintended consequence. The multi-battery underground charging bays are high-risk areas.” Fraser goes on to explain: “During the charging process, hydrogen is generated and escapes from the banks of batteries to form a potentially explosive mix. This could result in a catastrophic hydrogen gas explosion in the confines of the underground mining environment.” He warns that the situation could be even worse in a colliery, where hydrogen combustion may potentially trigger a more serious secondary coal-dust explosion. Solutions Fraser advises that effective solutions to mitigate the industrial safety challenges, which are caused by the presence of hydrogen gas in battery charging areas, are available from RTS Africa Engineering. RTS stocks hydrogen detection instruments from its California-based principal, H2Scan. • Battery charging stations “Our Hy-Alerta 500 and Hy-Alerta 600B or 610B models serve as a valuable safety

May - June 2018

• Area monitoring Designed for either ceiling or wall mounting, H2Scan’s Hy-Alerta 600B or 610B fixed-area hydrogen leak detection monitors are better suited for area monitoring and can provide hydrogen-specific leak detection and measurement for hydrogen concentrations as low as 4 000 ppm. The instrument can be connected to a flashing light or an alarm siren. Highest international standards In terms of occupational health and safety certification, H2Scan’s instruments conform to the highest international standards. H2Scan’s hydrogen-specific sensor technology has no cross-sensitivity with other gases, effectively eliminating false positive alarms and augmenting reliability. The hydrogen analysers and leak detectors are based on patented, solid-state core hydrogen sensor technology, exclusively licenced from the US Department of Energy. Through measurement capability that the abovementioned solutions provide in industries such as mining and petrochemicals, RTS Africa would like to see mine operators operate with peace of mind confident that the risk of hydrogen combustion has been eliminated. 45


Lockout tag-out

Improved safety with blind lockout and safety lock box When all levers, handles and buttons that control the energy supply to a machine are blocked with a lockout device and a padlock in line with procedure, all maintenance accidents related to prematurely reenergising machinery can be avoided.

A range of lockout tag-out products from Brady Corporation

i. Safe blind lockout for the widest range of pipes Brady Corporation offers a new pipe blind lockout solution that can be applied to the widest range of pipes. By easily and temporarily locking pipe blinds in place, companies can improve safety by preventing the release of gas, steam and hazardous liquids while pipe maintenance is ongoing. It has numerous advantages. Increased safety and compliance The Pipe Blind Lockout can provide a very 46

visual, physical barrier that acts as a deterrent for touching pipe blinds while maintenance is ongoing. When used with a properly installed pipe blind, the lockout device anda padlock reduces the risk of accidental release of pipe contents. This enables companies to increase workplace safety and also improve compliance with EU Guidelines 89/655 and the European Norm 1037. Non-sparking material The Pipe Blind Lockout has been UL tested for ISO 80079-36:2016 Explosive Atmospheres and falls within the parameters

of the norm. The device is built out of a heavy duty 304 stainless steel with rugged, cast aluminium locking bars and a powder coated polyester finish. Widest range of pipes With 3 sizes to choose from, Brady's Pipe Blind Lockout is applicable on the widest range of pipes, including all pipe diameters from 13.2 mm to 1219.2 mm. The device's extendable locking arm enables users to optionally lock not 1, but 2 pipe bolt sets for additional security. Up to 4 workers can apply a padlock directly on the device. May - June 2018


ii. Efficient maintenance safety with the new Lock Box Brady Corporation's new Ultra Compact Lock Box enables safer maintenance operations with Lockout/Tagout in an efficient way. The box can store and carry up to 6 padlocks and keys, and can be locked by up to 12 padlocks, making it a highly practical tool for teams and across shifts to keep machine energy control points locked in the off-position until maintenance is done. Easily store and carry The Ultra Compact Lock Box is ideal to store and carry up to 6 standard padlocks and can be mounted on a wall near machinery to make padlocks easily available. The hard plastic box also includes 3 hooks to hold keys and is equipped with a

transparant cover to enable a content check at first glance. The box can be locked by up to 12 padlocks, enabling larger teams to isolate a machine from its energy supply until maintenance is done. Safer maintenance When all levers, handles and buttons that control the energy supply to a machine are blocked with a lockout device and a padlock in line with procedure, all maintenance accidents related to prematurely re-energising machinery can be avoided. For larger teams however, one padlock per handle or lever may not be enough, and a lock box is needed to store the keys that can reenergise machinery. The lock box in turn can be locked by the padlocks of up to 12 team members who can all remove their lock after

finishing their work before re-energising the machine. Compliance Lockout/Tagout, which includes company specific lockout procedures, a range of devices to block energy control points, padlocks and accessories, helps companies be compliant with norms and regulations, including EU Directive 89/655/EEC about protecting employees servicing equipment, norm EN 1037 to prevent equipment from re-energising, ISO 14118 Prevention of Unexpected Start-up in addition to national legislation in a number of countries. Get product specifications or the free guide 'Enable safer machine interventions’.

Get the free Lockout/Tagout guide book via: www.bradyeurope.com/ pipeblindlockout.

THE COMPLETE 3 IN 1 SOLUTION FOR AN OPTIMAL LOCKOUT/ TAGOUT IMPLEMENTATION With best practice machine-specific procedures, software to easily create and evaluate them, and the tools to isolate any machine from its energy supply, you can avoid accidents during machine interventions and push your go for zero programme to the next level! Lockout/Tagout Guide Book

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Request the Lockout/ Tagout guide book “Safer machine interventions”!

www.bradyeurope.com/LOTOservices BRADY South Africa T: +27 11 704 3295 F: +27 86 501 7775 emea_request@bradycorp.com

May - June 2018

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Cable management

Reliable cable experience With the specific demands that exist within the mining world, it is imperative that when choosing a cable management partner, the stakeholder companies consider the experience that the prospective supplier has within the sector.

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able management solutions specialist, Strutfast, has become the most widely recognised African cable management brand for the mining sector, having successfully supplied its solutions to hundreds of mining projects across the African continent. “Strutfast has developed an enviable international reputation for meeting the demanding requirements of the arduous cable management applications that are specific to the African mining sector,” says Strutfast Managing Director Tony Kinsella. “With the specific demands that exist within the mining world, it is imperative that when choosing a cable management partner, the stakeholder companies consider the experience that the prospective supplier has within the sector. We have successfully supplied our cable management solutions to numerous mining projects across the African continent, ensuring peace of mind for the integrity of the power cable support structures for those mining operations” Strutfast, the Johannesburg, South

Absolute quality is at the heart of Strutfast, he adds, noting that its Business Management System has been developed to meet all of the requirements of ISO 9001.Strutfast is also committed to the broad-based black economic empowerment (BBBEE) initiative. “We are a Level 4 BBBEE contributor and have a 51% black ownership through an innovative staff trust, which ensures the upliftment and ongoing personal development of our 95 strong workforce.” Further, Kinsella notes that its indepth knowledge and experience in cable management solutions, along with its commitment to total project lifecycle support, from design to installation, training and maintenance advice, provides its customers with full confidence for any of their cable management projects. “An impressive client base of highly respected global companies, have entrusted their cable management solutions to the team at Strutfast,” he concludes.

Africa based Company, established in 2001, designs, manufactures and supplies costeffective cable management systems for all industries and through its experience in value engineering and innovative product design, Strutfast aims to reduce costs across the entire scope of a client’s project. “With an emphasis on innovation and full project lifecycle support, Strutfast has the technical design skills, manufacturing capability and logistics expertise to ensure that our customers can complete their projects on time and within budget,” says Kinsella. “Strutfast is focused on providing high-quality solutions to meet and exceed even the most arduous project requirements, especially for mining and power applications. Our cable ladders are fully and independently tested to meet and exceed the requirements of National Electrical Manufacturers Association (NEMA) standards 20B and 20C,” Kinsella highlights. Strutfast has branches across South Africa, distributors in many African countries and will shortly be opening their Australian sales office in Perth, Western Australia.

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May - June 2018


Cable ladder solutions designed for the most EXTREME conditions. All are manufactured and tested for the most arduous mining applications and are compliant with all relevant local and International standards.

STRUTFAST - leading the African continent in cable management solutions

www.strutfast.co.za A PROUD SOUTH AFRICAN COMPANY

Tel: +27 (11) 473 1212


Remote Area Lighting Systems

Safety Certified Lighting Innovations Pelican Presents its ATEX and US Safety Certified Lighting Innovations at East Africa Oil & Gas Exhibition. From bright Xenon lamps to powerful next generation LEDs, these safety approved lights include models featuring up to 392 lumens and a run time of up to 98 hours. The latest additions to this range are the revolutionary 3315RZ0 and 3315RZ0-RA rechargeable LED torches with a life expectancy of over 2,000 cycles, 4 times more than the 500 cycles that batteries usually last.

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elican™ Products, the global leader in the design and manufacture of advanced portable lighting, offers the perfect array of safety certified lights for professionals working in Oil & Gas Refineries, Offshore Platforms, Fire Brigades, Mining, Petrochemical, Pharmaceuticals or other high-risk industries. For their everyday projects, professionals can be confident that Peli offers the right products with the safety approvals needed for a large variety of risky situations. The company offers over 60 lights with European ATEX Certification (Zone 0 and Zone 1) and USA Safety approvals. A selection of these solutions will be showcased at the East Africa Oil & Gas Exhibition (Stand A05). 50

Wide Range of RALS including the First Safety RALS for Global Use Remote Area Peli™’s Lighting Systems (RALS) bring fully portable, rechargeable light to remote areas and emergency scenes. With multiple heads, multiposition deployable masts and Bluetooth activation (on

selected models), RALS are extremely versatile and offer up to 28 hours of bright LED light. The silent, rechargeable sealed battery allows users to work virtually anywhere without the use of a generator. With the new 9455Z0 RALS the company provides the safest product in its category thanks to its three global safety certifications: The European ATEX Zone 0 (Cat. 1), IECEx ia and North American CI, D1. All of them make it the perfect choice for working in hazardous locations where flammable vapours, gases and chemical compounds may be present.

Safety Approved Torches and Headlamps - ATEX Certified Zone 0&1 Peli™ offers an extensive range of torches and headlamps with Safety approvals. They comply with the highest standards of the ATEX Directive 2014/34/EU and meets the IEC (International Electrotechnical Commission) requirements. From bright Xenon lamps to powerful next generation LEDs, these safety approved lights include models featuring up to 392 lumens and a run time of up to 98 hours. The latest additions to this range are the revolutionary 3315RZ0 and 3315RZ0-RA rechargeable LED torches with a life expectancy of over 2,000 cycles, 4 times more than the 500 cycles that batteries usually last. For more information on full Pelican and Peli ranges, you can visit: www.pelican.com and www.peli.com May - June 2018


Dakar 2018

AT TH E INTE RSECT ION O F S AFE T Y AND POWE R FU L TEC HNOLOGY

East Africa Oil & Gas • Stand A05

3 7 15Z 0 RIGHT A NG L E Up to 189 lumens ATEX Certified Zone 0 (Cat.1)

OVER 60 S AFE T Y CERT IF IED MODELS US and European safety approvals

3 3 15RZ 0- R A TO RCH Life expectancy of +2.000 cycles ATEX Certified Zone 0 (Cat.1)

Since 1976, Pelican Products has been the global leader in design and manufacture of advanced portable lighting systems, including Safety approved flashlights, and tough case solutions. Our products are used by professionals in the most demanding markets including Oil & Gas, Fire & Rescue, Industrial and Defense.

9 455Z 0 R A LS The World’s first RALS with ATEX, IECEx ia and CI, D1 certifications

PELICAN PRODUCTS SOUTH AFRICA: Tel +27 83 645 4330 • sanette.nel@peli.com EMEA HEADQUARTERS: Peli Products, S.L.U. • Spain • Tel +34 93 467 4999 All trademarks are registered and/or unregistered trademarks of Pelican Products, Inc., its affiliates and/or subsidiaries. See Pelican.com for full warranty details.

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Mobile OTR tyre processing solution for mines

Turning tyre trash into treasure lawfully TREECYCLE Pty Ltd t/a- , Tyre Recycling Equipment SA, provides its OTR handling technology to Waste Beneficiation (Pty) Ltd, a company that offers a turnkey mobile solution for any OTR tyre stockpile. OTR Legacy and Post Legacy Tyre Stock piles Challenges TREECYCLE Pty Ltd highlights the following as OTR Legacy and Post Legacy Tyre Stock piles challenges: Size of the Tyres Difficult to handle and downsize to feed into a beneficiation process • Transportation of OTR Tyres • Abnormal loads • Cost: Distance from mine to processing facilities

This and others images- OTR tyre handling solutions

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he National Environmental Management: Waste Act, 2008 (NEMWA) which came into effect on the 1 July 2009 introduced an Extensive legal framework which emphasises management of waste i.t.o. the Waste Management Hierarchy. One of the main objectives of NEMWA is the diversion of waste from landfill and utilisation of waste where possible. OTR (Off The Road) waste tyres are no exception, as they pose a variety of challenges to the generator, with no viable solutions having been available on how to manage them.

TREECYCLE Pty Ltd’s role Conveniently, for mining companies and related industries in South Africa and neighbouring countries, TREECYCLE Pty Ltd t/a Tyre Recycling Equipment SA has an effective solution to help in addressing the problem of tyre waste management. The company has introduced the solution after realising that the magnitude of the OTR waste management is more complex beyond most the capability of many organisations. Mainly, the problems relate to the tyres, transportation, and legal implications with reference to relevant regulations.

Legal Implications in terms of NEMWA, ECA etc. • Cost to license and permit Permanent Static processing facilities • Abatement Plans, storage and stock pile management • Availability of Licensed offtakes and processing facilities or licensing such facilities Viable OTR Tyre solutions • Distance from mines to the processing facilities • Downsizing of the OTR tyre for acceptance to a processing facility • Capital Investment of available Permanent Static processing facility • Oversized Tyre Reduction Equipment solutions not readily available Health and Safety Issues • Fire hazard • Handling of OTR Tyres Major technology provider TREECYCLE Pty Ltd t/a Tyre Recycling Equipment SA provides its OTR handling technology to Waste Beneficiation (Pty) Ltd, a company that offers a turnkey mobile solution for any OTR tyre stockpile. Waste Benefication operates specifically in the OTR waste tyre downsizing industry. Established in 2013, the company is a Level

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May - June 2018


1 BBBEE Contributor, with 100% black ownership, and a management structure that is 100% black of which 20% are female. Waste Beneficiation is NEMWA compliant and have been appointed by the Waste Bureau. Currently, the company works on Anglo Platinum Mogalakwena mine downsizing the Waste Bureau OTR Tyres. The total tonnage to date at the current site is 8500 tons. The plant can pre-process 20002500 per month. As Waste Beneficiation’s Major Technology provider, TREECYCLE Pty Ltd t/a Tyre Recycling Equipment SA, represents USA companies, Eagle International and Saturn Granutech. Eagle International and Saturn Granutech companies are the leading U.S. providers of quality tyre-recycling equipment with representation in the U.S. and international markets. They are the ONLY supplier of complete OTR downsizing systems. All the equipment is supported locally, together with the Saturn Granutech Shredders, to achieve any required output size including 50 Mesch powder. The solution’s scope The downsizing OTR and Mining waste tyres Solution covers the following steps: Step 1 Pull the steel bead bundles from the OTR tyres Step 2 Bagel cut the tyres into two halves through the centre of the tread Step 3 Cut the tyres into pie shaped sections. Step 4 Shred tyres to meet offtake specifications Once the Tyres have been shredded, the rubber becomes a viable resource and is transported by Waste Beneficiation to a variety of offtakes: • Cement Kilns • Pyrolysis Plants • The Scrap steel will be transported to a licensed Scrap Steel offtake.

mechanical means using hydraulic handling and positioning equipment, cutting arms/blades and lifting equipment; and • No thermal process is applied in managing tyres. • The plant does not use water for preprocessing. Output • The downsizing system with the primary shredder can process 6 of, 59/80R63 tyres per hour – around 25 to 28 tons per hour. • The secondary shredder with screening can process between 12 and 15 tons per hour of 50mm output size rubber. Rapid, lawful deployment of solution on-site solution The proposed on-site solution could be implemented lawfully with immediate effect, provided that the operational footprint

thereof does not exceed 1000m2. Further, the downstream utilisation of the separated components (Steel beading, sliced tyre segments, shredded tyres pieces) can also be lawfully implemented. All of Waste Beneficiation off-site facilities (as proposed under the solution) are appropriately licensed and registered in terms of the Gauteng Waste Information System. Waste Beneficiation is also registered as a general- and hazardous waste transporter in terms of the aforementioned system. Waste Tyres are, furthermore, preclassified general waste under Annexure 1 to the Waste Classification and Management Regulations of 2013 (GN R 634 of 23 August 2013). As such, the waste tyres or processed sections would not lawfully require classification in terms of SANS10234. Nor would this waste require a SANS 10234 16-point safety data sheet (SDS) or an Assessment for Landfill Disposal in terms of GN R 636 of 23 August 2013.

After a task is finalised, the tyre downsizing equipment is completely mobile and can be moved from site to site. Vital information TREECYCLE Pty Ltd highlights the following points about its solutions: • The physical tyre processing can take place on an operation footprint of > 1000m2, • The tyres are processed through purely May - June 2018

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THE ONLY COMPLETE MOBILE SOLUTION TO OTR TYRE RECYCLING

Step 2: OTR Punch Cutter MK II / Cutting Tyre into 2 halves around circumference The Eagle mobile Punch Cutter MK II has been designed to cut the OTR tyre into two halves by cutting directly down the center of the tire tread. The machine processes any size of OTR tyres with a minimum rim size of 33” and including the largest tyres in the world, the 59/80 - R63 and the 70/70 – 59.

Step 1: OTR De Beader / Removing the Steel Bead from Tyre The OTR De-beader is designed to pull the steel bead bundles from giant OTR tires, allowing the steel from these tires to be recycled. The machine removes the steel beads from radial tires with a 25 inch rim opening all the way up to, and including, 63 inch rim openings (e.g. . 59/80 - R63). The Eagle OTR De-beader has been designed with adjustable die plates which allow the operator to pull both bead bundles simultaneously for rim sizes of 25 inches through 51 inches. The machine will pull one bead at a time for sizes above 51 inches up to 63 inches due to the increased size and weight of the beads.

The Eagle mobile OTR Titan II is often referred to as a “work horse” unit. The Titan II has the ability to handle and cut large OTR Mining tires into segments of around 250 kilograms, making it easy to load into small or large shredders for further reduction.

OTR Tyre Steel Bead extracted from Tyre +- 180 kg steel per bead

Cut OTR Tyre Segments to feed into Mobile shredder

Step 3: OTR Titan II / Cutting Bagel halves into segments


Eagle International Oversized Tyre Reduction Equipment & Granutech Saturn Shredders Granutech Tyre Shredder Systems Mobile and Stationary Tyre Shredders

Granutech Primary shredder with self loading grapple and cab

Granutech mobile secondary shredder with sizing and sorting capabilities

Granutech also supply entire plants that downsize tyres any required output size including – 50 mesch , steel and fibre free ( 99.9%) powder.

"Quality Equipment only needs to be purchased once!" Treecycle (Pty) Ltd is the official dealer / distributor of Eagle International Tyre Equipment and Saturn Granutech Shredding Systems in Africa !

Telephone: 022 7720307 Fax : 086 6085903 Email : shaughn@tyrerecycling.co.za Web: www.tyrerecycling.co.za B-BBEEE Level 2 Contributor | CSD Registered


Condenser tube cleaning

Cleaner condensers for peak plant performance Condenser maintenance of a coal-fired power plant is a ‘pay me now or pay me later’ proposition. It has to be done rightly or else an organisation will spend hundreds of thousands, if not millions of dollars, address low performance.

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ondensers are central to a coal-fired power plant’s efficiency, but, there is only on one condition – when there are clean. On the other hand, dirty condensers can become a liability to a plant, more especially when they compromise power generation capacity, which is the whole essence of running a power plant. There are several conditions that can choke a condenser tube. In what is known as fouling, most condenser circulating water sources contain dissolved solidus like iron, manganese, or calcium carbonate (calcite) become deposited on the inner surfaces of the tubes and clogging the tubes. African Mining Brief examines views from experts on condenser tube fouling, with reference to the following areas: common problems that are encountered, how they impact on condenser performance, and determining the best cleanup method. Eric H Fayard is the Business Development Manager of ReTubeco Incorporated. George Saxon, Jr. is the VP of international sales and marketing for Conco Systems Incorporated., a company whose line is cleaning and maintaining condenser tubes, which is based in Pennsylvania, USA. Energy Exchange is an information portal managed by the Department of Energy in Australia. Classifying condenser tube fouling Fayard classifies condenser tube fouling, which quintessentially affects the interior of a tube, in the five categories: Microbiological Fouling, Scale Fouling, Particle Deposition Fouling, Corrosion Products Fouling, and Tubesheet Pluggage 56

aquatic animals (crayfish, fish, and clams). Major problems Saxon, Jr. mentions two major problems that dirty tubes can cause - reduced heat transfer and under-deposit corrosion.

Condenser tube cleaning in process (Pic credits: Concor)

• Microbiological Fouling Microbiological fouling routinely occurs in natural waters, as many bacterial species will naturally colonise and grow on inert substrates. The temperature at the interior wall of condenser tubes is ideal for growth of some bacteria. • Scale Fouling Scale (mineral crystallisation) occurs on heat transfer surfaces under a combination of dissolved mineral concentration and temperature effects. Scaling of certain common constituents in natural waters (such as calcium carbonate and calcium phosphate) is promoted by elevated temperatures, such as exist on the interior wall of condenser tubes, particularly toward the outlet end. Other scaleforming minerals (including calcium sulfate) are more likely to form at cooler temperatures. Scale can drastically reduce heat transfer, depending on the specific mineral formed and its thickness. Although scaling water chemistry is not normally associated with corrosion, it is very possible that crevice corrosion will occur beneath scale.

• Particle Deposition Fouling Particle deposition generally occurs in condenser tubes when the flow rate is inadequate to keep particulates in suspension. Design flow through condenser tubes is often 7 to 10 ft/s, but this is an average (bulk flow), and some tubes may experience much lower flow than others. Corrosion Products Fouling Corrosion products can grow relatively thick on the surfaces of certain tubes, primarily copper alloys. Scale or deposition promotes copper oxide growth, and in some cases a thin surface scale will enhance the growth of a thick underlying copper oxide layer, which will inhibit heat transfer and establish sites for crevice corrosion. • Tubesheet Pluggage Macro fouling can include blockage at the tubesheet and within the tubes by various materials and debris, including rocks, concrete pipe debris, cooling tower materials (plastic fill/wood), chunks of ash or coal, pieces of rust, paper trash, leaves and other vegetation, and

• Reduced heat transfer Poor conditions in condensers can reduce heat transfer and cause high fuel consumption. In extreme cases, poor vacuum conditions in the condenser can reduce generating capacity by more than 50%, Saxon notes. Eric H. Fayard corroborates this view, observing that fouling can affect not only unit heat rate but also the ability of the turbine to generate its design load capacity. “In fossil-fired plants, an increase in heat rate is reflected in higher fuel costs for a given load, and increases of 2% are not uncommon. In both fossil and nuclear plants, if the fouling becomes severe, it will cause the backpressure to rise to its upper limit, forcing a reduction in generated power,” he states, adding that dirt in condenser tubing impedes the flow of water, reducing the efficiency of steam turbine operation. • Corrosion Above and beyond increasing fuel consumption and reducing heat transfer properties of a condenser, dirty condenser tubes advance corrosion. If deposits are not removed periodically, the corrosion may penetrate the tube wall, allowing circulating water to leak into and contaminate the condensate.

Read More of this article on: http://ambriefonline.com/ May - June 2018


Moisture belt analysers

The application of Moisture Measurement Techniques to Process Materials

The ultraMOIST Microwave Moisture Monitor

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oisture measurement has always been an important process parameter which has traditionally been carried out using the conventional laboratory analysis of a manual sample. This is an expensive and time consuming process with the time taken to provide the result meaning that the information is usually only of historical value. During the time interval between taking the sample and reporting the result, it is likely that operational conditions will have changed so that the reported result is no longer valid to the prevailing conditions. Technologies Historically there have been several technologies applied to the measurement of process materials including: Conductivity These systems typically consist of probes inserted into the process stream and so are prone to wear. They are also prone to error due to varying degrees of contact with the material. Capacitance These system provide very little sample penetration and cannot be used on steel cord reinforced conveyor belts. The dynamic range is very limited Back Scattered Microwave These system consist of probes that are designed to be installed directly into the process stream and so are prone to wear. Near Infra Red This technology provides a measurement of the surface moisture only and is affected by the colour of the material, sample geometry and ambient lighting. The distance of the process material from the sensor can also affect the measurement.

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Transmission Microwave The advent of the ultraMOIST Microwave Moisture Monitor now provides a low cost moisture measurement system with the following benefits by removing the following potential Limitations: • No vertical segregation effects - the microwave beam penetrates the full bed of material. Unaffected by variable bed depths of material present on the conveyor belt – a mass flow device is used to compensate for different bed depths • Changes to the colour of the process material colour does not affect the measurement. Changes to ambient lighting does not affect the microwave reading • Non contact technique so there are no wear problems • The presence of steam does not affect the reading • System designed for arduous industrial environments – IP66 enclosures The ultraMOIST On-Conveyor Microwave Moisture Monitor (ultraMOIST) now allows the accurate measurement of moisture in real-time. This ready availability of moisture information allows proactive process control actions. The information can be used in a number of ways including: • Metallurgical/process accounting • Feedback control to a dryer circuit • Feed forward/back control to spray bars for dust control • Product net weight monitoring for quality control purposes • Product moisture/dry mass contract compliance • Diverting excessively moist material away from vulnerable downstream processes May - June 2018


Heavy duty cranes

Water-bags for load testing Load testing of cranes is a vitally important part of Konecranes’ service and maintenance programme, especially where older cranes are concerned.

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ccording to the Engineering Council of South Africa (ECSA), all lifting machines, which are classified according to different Codes in Appendix 12 of the Occupational Health and Safety Act (OHSA) OHSA, Department of Mineral Resources (DMR), must be load tested (performance tested) at intervals not exceeding 12 months. This load test must be conducted by a Department of Labour (DOL) registered LME (Lifting Machinery Entity. This actual load test must be conducted, or be supervised by an ECSA registered LMI (Lifting Machinery Inspector registered with ECSA). And in recognition of legislation, load testing of cranes is a vitally important part of Konecranes’ service and maintenance programme, especially where older cranes are concerned. In order to speed

up the load testing and avoid downtime, all Konecranes branches are now equipped with their own water bags. Mobile Test Crane for load testing Konecranes South Africa have also designed and manufactured a Mobile Test Crane for load testing on site. The customer no longer has to wait for his lifting equipment to be returned to site, as all the units are tested on the customers' premises, in their presence. It is unique as it can print the Load Test Certificate on the spot. Lifting equipment is certified proof load tested in accordance with all safety aspects and regulations. This rig can test from chain blocks (manual and air driven) to lever hoists, coffin hoists etc. The Mobile Test Rig can handle a 30T capacity and it has

a heavy duty battery back-up where electricity is not available. The advantage of testing in this manner has proven far better and much quicker, improving Konecranes' service. “Our investments in fully equipping our branches with mobile test rigs and our own static weights and branded water bags has already proved to have tremendous benefits and advantages,” says John MacDonald, Service, Sales and Marketing Director of Konecranes. “It has most certainly raised the bar in our industry and set new and higher standards in service delivery. Productivity-enhancing lifting solutions Konecranes is a world-leading group of Lifting Businesses™, established in Finland over 100 years ago, serving a broad

Productivity-enhancing lifting solutions from Kone Cranes

range of customers, including manufacturing and process, industries, shipyards, ports and terminals. Konecranes provides productivity-enhancing lifting solutions as well as servicing for cranes and hoists of all makes. The Group has 12,100 employees, at 626 locations in 48 countries, including ten branches in South Africa (Johannesburg, Port Elizabeth, Durban, Cape Town, Witbank, Klerksdorp, Rustenburg, Ngodwana, Richard Bay and Kathu)

WE LOVE ALL CRANES EVEN THE ONES WE DIDN’T MAKE

Service, Repair and Load Test of all Makes of Cranes and Hoists

+27 (0) 898 3500 * +27 (0) 76 403 3185 John.MacDonald@konecranes.com May - June 2018

HBPR/K140

www.konecranes.co.za

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Hybrid power generation

Determining the most reliable and lowest cost power solution Juwi Renewable Energies tells African Mining Brief about key issues that mines can prioritise when assessing the viability of utilising hybrid power.

The longer the life of mine, the more attractive will be a hybrid solution

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he benefits of hybrid power technology for mining companies have increased significantly in the past few years and can now be compared against operational projects like the SandfireDegrussa Copper-Gold mine. Dithering on making crucial decisions on energy sources can have a costly impact on a project in the medium to long-term. According to what African Mining Brief has gathered in an interview with Arnim Schön, Sales Manager Sub Saharan Africa at juwi Renewable Technologies (Pty) Ltd, investing in renewables today can provide substantial operational benefits, power price security and maximise shareholder value. Schön supports mines on how to best handle the following areas: Feasibility and Planning Stage, Rental vs Power Sale or Plant Ownership, Implementation, and Post-commissioning Support. Key factors There are a number of aspects that determine the most reliable and lowest cost power solution. , For hybrids the following aspects are are vital: Life of Mine, 60

Power costs, Mine location (grid connected or grid) and Hybrid System Integration, as captured below, advises Schön. • Life of mine Renewable energy technology has matured and reduced in cost to a level that it can provide Cash Operating Cost reductions for many mines with Life of Mine of 5 years or more. The longer the life of mine, the more attractive will be a hybrid solution. • Power costs The current or planned cost of power without hybrid serves as the benchmark to determine if solar, wind or batteries could deliver power at the same or at lower costs. Schön adds: As a rule of thumb renewables will improve Cash Operating Costs for most mines that have 5 or more years of mine life ahead of them. • Mine location: Grid connected or off grid If a mine is connected to the grid, solar or wind power plants behind the meter produce power cheaper than the grid in

most cases. Even if there is not enough land available or the local wind or solar conditions are not favourable, power could also be wheeled contractually from a different location. In both cases, notes Schön, the hybrid solution will mitigate risks from unstable grids or future price increases. “Combining solar with battery storage will also aid in power smoothing to further absorb the impact of an unstable grid as well as balancing power output during cloud events for example.” If a mine is off-grid and runs on Diesel, LFO or HFO generators, a hybrid solution will likely save even greater amounts in Africa, he advises. “A hybrid power plant incorporating solar, storage or even wind will significantly reduce the fuel costs and carbon emissions. If you consider that up to 85% of the cost of electricity of a thermal plant comes from fuel costs the magnitude of savings become visible. On top of that, a hybrid solution will provide additional savings on O&M of the thermal power plant,” he remarks. • Hybrid system integration Integrating solar, battery or even wind into thermal power stations at mine sites is not as simple as designing and building a solar rooftop for a home or a standard grid connected plant. A powerful, robust and reliable hybrid microgrid controller and SCADA system are as essential for project success as the integration expertise and experience in mining environments. On how juwi handles this challenge, Schön explains, “Despite being a technology

agnostic EPC and project developer juwi could not find a suitable SCADA solution that could properly cover all generation assets. That is why we have developed and successfully deployed our own juwi hybrid SCADA. juwi’s hybrid SCADA has been running now successfully since 2016 at the Degrussa Copper/Gold mine in Australia.” • Location and resource area Last but certainly not least, Schön mentions the wind and solar resource and the availability of land as central to the planning of a hybrid power generation plant “The first question to be asked is: Does the mine have the space and suitable land for constructing a solar plant or the ability to wheel power from elsewhere? As a rule of thumb for Africa, a solar power plant requires 1 to 2 ha per Megawatt capacity. “The second question is: Is the mine in a good solar or wind resource area. With regard to Africa, juwi has established that, providentially, almost all African locations have enough sunshine and some locations have excellent wind conditions,” Schon states. Rental or ownership? Outsourcing is all the rage in contemporary mining conditions. This has led to the fallacious notion that rental rather, power sale agreements or ownership is the most aviable option for mining companies. But Schön begs to differ, at least based on juwi’s experience. On the contrary, argues Schön, the reality is that the decision on whether to rent, enter into an energy sale agreement or purchase a power plant, depends on the duration of a contract. “One can say that renting of gensets has its place in a mining environment but is normally seen as a gap filler for something more permanent and cheaper in the future. For contracts with only 1 to 3 years, rental might be financially sound.

Read More of this article on: http://ambriefonline.com/ May - June 2018


African Mining Brief  

African Mining Brief 2018 Issue Vol 13 No.3 Africa's leading bi-monthly magazine for the mining industry in Africa, bringing you all the bes...

African Mining Brief  

African Mining Brief 2018 Issue Vol 13 No.3 Africa's leading bi-monthly magazine for the mining industry in Africa, bringing you all the bes...