VULCAN INTERNATIONAL: A NEW ERA IN MINING, COMMUNITY DEVELOPMENT, AND SUSTAINABLE GROWTH
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VULCAN INTERNATIONAL: A NEW ERA IN MINING, COMMUNITY DEVELOPMENT, AND SUSTAINABLE GROWTH
Vulcan International’s transformation from a regional player to one of the world’s foremost coal companies is a compelling story of ambition, innovation, and strategic vision. Since acquiring the Moatize Coal Mine in Mozambique in 2022, Vulcan has rapidly ascended to become the globe’s largest integrated pit-to-port coking coal supplier. Under the leadership of Dr Mukesh Kumar, CEO, the company has revolutionised its operations, expanding its production capacity while embedding sustainability and community development at the core of its business model.
Dr Kumar’s career in mining has been defined by a progressive, forwardthinking approach, with an unwavering commitment to both operational excellence and social responsibility. "Our mission is not just to extract resources," Dr Kumar asserts, "it is to create long-term value for our stakeholders, including the communities we operate in." Vulcan’s commitment to growth is built on a foundation of innovation and
forward-looking investment, ensuring that Mozambique, often overlooked by global corporations, has become a pivotal location for both economic development and sustainable resource management.
The acquisition of the Moatize Coal Mine, one of the world’s largest coal reserves, marked a turning point for Vulcan International. With an estimated 2.4 billion tonnes of coking coal, the mine presented a wealth of untapped potential. Yet, the challenge for Vulcan was clear, optimise existing infrastructure and increase production capacity.
"When we acquired the mine, it was underutilised, operating at less than half its potential," Dr Kumar explains. “The infrastructure was in place, but we needed to drive efficiencies, implement modern technologies, and tackle bottlenecks that had limited production.”
In just three years, Vulcan has successfully raised its mine output from 22 million tonnes in 2022 to an expected 45 million tonnes by the end of 2025, resulting in production of export grade Coking and Thermal Coal to around 17
VULCAN INTERNATIONAL PROJECT DIRECTED BY: ADEL MHIRI ARTICLE WRITTEN BY: LAURA WATLING
TATA UMPESL adds value for mining industry
Emerging mining machinery solutions
provider TATA UMPESL continues to add value to the global mining industry by maintaining earthmoving equipment for a lower cost than other agents in the market.
The focus of this approach, the company explains, is to provide project owners and managers the opportunity to “solely concentrate on their operations and leave the headache of complete maintenance of these big machines to us”.
Value-added Services
In the global opencast mining sector, heavy mining equipment is the backbone of the production process. As such, the uptime of equipment is the primary focus of any mine operator.
TATA UMPESL says its service “assures high availability and reliability of the equipment”, leading to a “considerable difference in overall performance”, allowing it to “reduce the cost per ton of product” and comprises:
A service agreement, to ensure that equipment is being serviced according to standard procedures set by the manufacturer, so that the lifespan and reliability of the is ensured.
The attention of factory-trained experienced engineers and technicians that apply specialised skills to troubleshoot and maintain heavy machinery equipment comprising state of the art engineering products.
Mining and Construction Equipment Division
The Mining and Construction Equipment (M&CE) division is an ideal product support partner specialising in:
Turnkey erection and commissioning of ultra-large class mining machines.
Operations and maintenance contracts.
Rental contracts.
Annual service contracts & rehabilitation programmes.
Voltas’ six-decade-old M&CE equipment division has been a major player in the heavy and earthmoving machinery industry in India and has been credited with the launching in the Indian mining industry of many global brands of heavy and earthmoving machinery equipment.
Africa Focus
The company’s plans to “vigorously expand across Africa” follow on Voltas’ M&CE division having entered a strategic partnership with Tata Africa in 2010, through which it offers service solutions for mining machines operating in Mozambique at the Moatize coal mine of Vale Mozambique, now known as Vulcan International. Tata was among the few initial companies that signed contracts with Vale for providing maintenance support for its mining equipment fleet. Current contracts have been entered into with Vulcan International, Jindal Mines and Komatsu.
TATA UMPESL’ agile and proactive approach are based on the following values:
Service being the backbone for the sustenance of future growth in Africa.
Service support for the machinery and equipment’s life cycle being of utmost significance.
Services offered delivering considerable cost savings to large mining companies which seek to optimise production by rationalising cost.
With its solid experience in heavy machine maintenance, safety and quality policies, as well as familiarity with multicultural and multidisciplinary environments, the company is providing solutions globally to the equipment repair and maintenance needs of heavy industrial applications.
Services are provided on a 24/7 basis, and see Tata leverage its global presence and marketing capabilities to deliver value to its customers in the following five key business lines:
Metals
Distribution
Leather and leather products
Minerals, and
Agri-trading.
Comprehensive maintenance
Trouble shooting
Failure analysis
Component repair & rebuild
Bucket repair
Parts planning & Support
Training & development
Machine Assembly, Erection testing and Commissioning
Tata Brand name
Established set up
Proven track record
Technical competency
Customeracceptance
Principal support
Ability to take new challenges
Dedicated & hardworking team
WATCH OUR INTERVIEW WITH VULCAN INERNATIONAL CEO DR MUKESH KUMAR
million tons. Key to this dramatic growth has been a concerted focus on improving logistical operations. By reducing railway turnaround times from 130 hours to just 60, Vulcan unlocked significant potential, enabling the company to scale production while simultaneously cutting operational costs. “Logistics was one of the biggest challenges we faced,” Dr Kumar acknowledges. "By enhancing efficiency across the board, we could increase throughput without compromising quality or safety."
Vulcan’s commitment to quality has never wavered, even as it scales production to meet growing global demand. “We
Dr Mukesh Kumar, CEO
adhere to a zero-tolerance policy when it comes to quality,” Dr Kumar asserts. This focus on premium-grade coking coal has ensured that Vulcan’s product meets the exacting demands of modern steelmakers who operate large blast furnaces, a market segment that has seen an uptick in demand as the steel industry moves towards more sustainable practices. Vulcan’s coking coal is prized for its low sulfur and ash content, making it ideal for steel producers who are focused on decarbonisation and reducing emissions.
The company’s forward-thinking approach to quality is evident in its significant
VULCAN INTERNATIONAL
investments in technology. Through continuous innovation, Vulcan has refined its product to meet the evolving needs of its clients. Dr Kumar notes that major steelmakers, including POSCO, Tata, and ArcelorMittal, have come to rely on Vulcan’s coal, recognising the tangible benefits it brings to the quality and efficiency of their production processes. "Our customers are willing to pay a premium for our coking coal because they see the value it brings," Dr Kumar says. "It strengthens their coke, enhances blast furnace performance, and supports their sustainability goals."
Beyond its operations, Vulcan’s success is deeply intertwined with the development
of Mozambique and its people. “As we grow, so does the country,” Dr Kumar emphasises. Vulcan employs over 19.000, with a further 30,000 engaged in the supply chain, making the company one of Mozambique’s largest employers. "Our responsibility extends beyond profit," he says. "We are committed to fostering inclusive growth, creating opportunities for local communities, and contributing to the economic development of the country." In line with this philosophy, Vulcan has committed to ensuring that local communities share in the wealth created by its operations. The company’s social responsibility initiatives are vast, with a focus on education, healthcare, and local
Industrial Engineering Solutions
With a strong foundation and a forward-thinking approach, Duys continues to deliver excellence across Mozambique.
Founded in 2001, our journey began by providing maintenance services to BHP Billiton Mozal, establishing itself as a trusted partner in the industry. In 2018, the company entered a new chapter when it was acquired by two Mozambican industrial investment firms, Escopil Indústria & Valoriza.
Under new ownership, a bold vision emerged, driving Duys to diversify its portfolio. Today, we proudly serve a wide range of industries, including mining, oil and gas, and port infrastructure.
1.Oil & Gas
• Upstream, Midstream, Downstream
• Fabrication, installation and maintenance of auxiliary equipment
• New structural steel fabrication & assembly
• Pipping & Mechanical Construction
• Wet Parking Frames Off-shore
• Energy and Heat Equipment
2. Aluminium Smelters
• Pot Shell fabrications, maintenance and repairs
• Superstructure maintenance and repairs
• Cathode Bar machining and assembly
• Anode Stem fabrication and maintenance
• Heavy steel structural projects
• Metal Laddles Fabrication
• Bath Laddles Fabrication
• Plant Maintenance and Upgrades
3. Material Handling & Ports
• Port Equipment fabrication, installation and maintenance
• Turn-key solutions with minimal impact on shutdowns
• Installation and maintenance of stacker reclaimers
• Fabrication, installation and maintenance of ship loaders
4. Mining
• Maintenance and repairs of steel structures
• Fabrication and maintenance of Dredge equipment
• Fabrication and maintenance of Barges
• Fabrication and maintenance of Conveyor Belts/Systems
• Fabrication and maintenance of Pump Skids
As part of the Escopil Group, Escopil Indústria is a benchmark in industrial engineering, committed to innovation, sustainability, and national development.
We have a strong presence in the mining industry, serving clients such as Vulcan, and we actively support the entire value chain – from CAPEX projects to maintenance. Our operations extend across Vulcan, and we are actively involved in: ✔ Metalworking & Electromechanical Engineering ✔ Hydraulic & Instrumentation Systems ✔ EPC Turnkey Projects ✔ CAPEX Projects & Industrial Maintenance
Mining, Aluminium & Cement Industry Support
Mozambique’s
XCELLENCE & REALIBILITY
ENGINEERING MOZAMBIQUE’S FUTURE
Founded in 2019, Esitech, LDA is a 100% Mozambican-ownedindustrialand technologycompanythatdelivershighimpactengineeringsolutionstothe heavyindustrysector.Headquarteredin Tete,Mozambique,Esitechservesasa trustedpartnertoleadingmining operations,utilities,andindustrial manufacturersacrosstheregion
Esitech’smissionistoleadinindustrial systemstechnologies,offeringcuttingedgeservicesthatmeetbothlocal demandsandglobalstandards.With astrongfocusonindustrialelectrical systems,powergenerationand distribution,instrumentation,and automation,thecompanyprovides comprehensive,end-to-endproject support—fromengineeringconsultancy andsystemstudies,toimplementation, integration,andongoingmaintenance
Backedbyamultidisciplinaryteam ofskilledengineers,Esitech’skey advantageliesinitsdeeplocal
CEO Virgilio Chicohe
knowledge, international compliance, and commitment to sustainable growth. The firm is already a key player in Mozambique’s mining and energy sectors and is poised for broader
expansion across the African continent.
Whether designing robust electrical systems, deploying automation technologies, or modernizing existing infrastructure, Esitech delivers efficiency, safety, and reliability at every stage of the industrial process.
We would like to express our sincere gratitude to Dr Mukesh Kumar CEO at Vulcan International, Vulcan Mozambique for, their invaluable support and partnership. Their trust in Esitech not only strengthens our mission but also inspires us to keep innovating and delivering world-class solutions for Mozambique and beyond.
Driven by innovation and grounded in local expertise, Esitech is shaping the future of industry in Africa.
www.esitechcorp.com
infrastructure. Vulcan has built schools, supported hospitals, and provided muchneeded medical resources. Through these initiatives, Vulcan has positioned itself as a responsible corporate citizen, working hand-in-hand with the local population to foster long-term socio-economic development.
At the heart of Vulcan’s corporate strategy is its commitment to environmental responsibility. Operating in a semiarid region, Vulcan faces significant challenges in managing dust and emissions. However, the company has implemented a sophisticated monitoring system that includes automated dust control technologies, water cannons, and advanced filtration systems to mitigate environmental impact. "We don’t see environmental protection as a box to tick," Dr Kumar says. "It is ingrained in our operations. We are committed to minimising our footprint and
VULCAN INTERNATIONAL
making a positive impact on the environment."
Vulcan’s environmental programs go beyond regulatory compliance. The company has committed to a circular economy approach, using coal waste to generate power and reduce reliance on imported diesel.
"Our waste-to-energy project is a prime example of how we are innovating to reduce environmental impact,"
Dr Kumar explains. "By converting coal waste into power, we not only reduce our carbon footprint, but we also provide clean, reliable energy to the local communities. This is sustainable growth in action."
Vulcan has also invested in green energy, with plans to build a 60 MW solar power plant that will provide electricity to surrounding communities. "Solar energy is abundant in this region, and
Pioneering Industrial Innovation in Mozambique and Beyond
SCAFFOLDING ENGINEERING SERVICES
MLS Scaffolding stands between the two biggest leading companies in the scaffolding, is also the largest 100% Mozambicanowned scaffolding company and the only scaffolding company certified in ISOS NM 450001:2018 & 9001:2015, holding 45% market share of the national market.
Contact info: Geral@mls-lda.co.mz Salvador.cuinica@mls-lda.co.mz
Founded in 2018, MLS Scaffolding is the only 100% Mozambicanowned scaffolding company whose operations comply with international standards such as Quality Management Systems and Occupational Health & Safety Management Systems, European Norms & SANS. With more than 180 employees, MLS has been operating for over 5 years in critical industries such as mining, oil & gas, and food & beverages, establishing itself as a trusted partner for leading companies across Mozambique.
Our services include:
• Erection and inspection of scaffolding
• Rental and sales of certified scaffolding systems
• Scaffolding for commissioning and industrial maintenance
• Rope Access & Rigging
• Specialized training in scaffolding erection, supervision, and HSEQ
• Scaffold Design & Calculation of Load Bearing Capacity;
• Professional Engineering Sign-Off of Scaffold Design;
MLS has over 2000 tons of scaffolding equipment, distributed all over different projects, including Vulcan, where we have more than over 400 tons of scaffold equipment
With over 80 key-projects successfully completed nationwide, our portfolio includes partnerships with AbInBev, Vale Moçambique, ENH Kogas, MGC, Bureau Veritas, GIMTL, Galp Mozambique, HIGEST, Aurex, PetroBeira, TechnipFMC at Coral-Sul FLNG offshore platform, consistently delivering solutions that meet the toughest international standards.
MLS is also engaged in Civil-Works, in which we have collaborated with companies such as Mota-Engil, Mozago, SS Cosntruções, Lda, WBHO, Teixeira Duarte Group
we are investing in it to benefit the local population," Dr Kumar adds. "We are committed to helping Mozambique reduce its reliance on fossil fuels and provide cleaner energy to support economic development."
Vulcan’s focus on sustainability is not just about reducing emissions but also about ensuring that its growth benefits the country and its people. "Our philosophy is simple," says Dr Kumar. "We want to leave a legacy of responsible mining, where the environment is protected, the community thrives, and the economy grows. That’s how we measure success."
Looking to the future, Dr Kumar’s vision for Vulcan is clear. By 2030, Vulcan aims to be a leader in responsible mining and sustainable development, setting the standard for how mining companies can operate profitably while contributing to society. "We are investing in advanced technologies, focusing on renewable energy, and striving to create a cleaner, greener future," he says. "Our vision is to show the world that mining can be both profitable and sustainable, and that the industry can play a pivotal role in the global shift towards sustainability."
As Vulcan International continues to scale and innovate, it is clear that the company’s growth is driven not just by operational efficiency but by its deeprooted commitment to the well-being of its people and the environment. Vulcan is proving that it is possible to create a thriving, sustainable mining operation that serves both corporate interests and the greater good. With Dr Kumar’s leadership, Vulcan is setting a powerful example of what responsible, forwardthinking mining can achieve—not just for Mozambique, but for the world.
www.vulcaninternational.com
Clean, Reliable, Unstoppable: The Future of Fire Suppression
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Proven in the toughest environments, Wireline Africa Limitada’s vehicle suppression systems recently passed rigorous international testing in Switzerland with outstanding results. This achievement confirms their reliability in demanding mobile applications, making them the ultimate choice for heavy equipment, transport fleets, and off-road vehicles.
From compact standalone units to advanced electrical in-cabinet systems and full-scale facility protection, Wireline Africa Limitada provides a complete portfolio of solutions powered by the same breakthrough technology. With precision mist distribution and an unwavering focus on innovation, the company is setting a new global standard in clean, efficient, and dependable fire protection.
Wireline Premier Downhole Geophysics reduces exploration costs and enhances geologic certainty in the extraction of minerals and unconventional hydrocarbon resources. With more than 70 years of global experience in downhole geophysical surveys, the company delivers highquality data in a fraction of the time required for traditional core sample analysis.
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