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THE KNOWLEDGE YOU NEED

ining FROM THE INDUSTRY EXPERTS

HOT SEAT

Mark Berger, Aurecon resources business development manager: on growing their mining client base

COAL The captivating commodity

MINERALS PROCESSING Introducing revolutionary concepts

The new rock solid earthmoving performer ISSN 1999-8872 • R35.00 (incl. VAT) • Vol. 5 • No. 4• April 2012

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CONTENTS

T H E K N O W L E D G E YO U N E E D

ining

April 2012

FROM THE INDUSTRY EXPERTS

Highly commended 2011 PICA Cover of the Year - B2B Publishing

www.miningne.ws

MEDIA

THE KNOWLEDGE YOU NEED

ining

ON THE COVER

FROM THE INDUSTRY EXPERTS

The new Terex TA400

HOT SEAT

Mark Berger, Aurecon resources business development manager: on growing their mining client base

Mining’s new rock solid earthmoving performer P6 COAL The captivating commodity

MINERALS PROCESSING Introducing revolutionary concepts

The new rock solid earthmoving performer ISSN 1999-8872 • R35.00 (incl. VAT) • Vol. 5 • No. 4• April 2012

EDITOR’S COMMENT

Coal – the star attraction, but for how long?

MINING NEWS

The top mining stories headlining this month

HOT SEAT

Aurecon – rallying clients and their projects

HOT TOPIC

Rand Refinery: aiming for another 90 years

ENERGY GENERATOR: COAL

14 20 24 30

Renewable energy – a possible downside for coal Underground coal mines – Keaton’s key to success Continental Coal – third quarter, third coal mine Sentula Mining aims to monetise its assets

COAL PANEL DISCUSSION

Services and equipment solutions for the coal sector

OPENCAST AND EARTHMOVING

46 48

Bell’s pre-owned muscle machines Basil Read Mining moves more than mountains

MINERALS PROCESSING

52 54 57 60

FLSmidth fills the process gaps Roymec Technologies revolutionises thickeners Radical reagents for rare earths Ingwenya Minerals Processing: a coal custodian

PROJECT DELIVERY: MOTORS

62 64 66

Delba’s mammoth motor ambitions A premium electric motor growth strategy A magic motor formula

CETERUM CENSEO

To Indaba or to PDAC? Inside Mining 04/2012

Editor’s comment Publisher Elizabeth Shorten Editor Laura Cornish laura@3smedia.co.za Creative Chief Executive Frédérick Danton Senior designer Hayley Mendelow Senior sub-editor Claire Nozaic Sub-editor Patience Gumbo Marketing Manager Martin Hiller Production Manager Antois-Leigh Botma Production coordinator Jacqueline Modise Financial Manager Andrew Lobban Administration Tonya Hebenton Subscription sales Nomsa Masina Distribution coordinator Asha Pursotham Printers United Litho Johannesburg

COAL

The star attraction, but for how long? The population’s general consensus is that the mining industry is rapidly returning to its all-time highs, and who would argue this? Not anyone directly or even indirectly exposed to the coal industry, that’s for sure!

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South Africa: R350.00 (incl VAT & postage) SADC countries: US$80 Foreign: US$100 ISSN 1999-8872 Inside Mining Copyright 2012. All rights reserved. ___________________________________ All material in Inside Mining is copyright protected and may not be reproduced either in whole or in part without the prior written permission of the publisher. The views of contributors do not necessarily reflect those of the the publishers.

My fascination

with this issue’s coal feature did not lead me to the big coal mining players (for a change), such as Exxaro and Xstrata Coal, but rather to the multitude of junior (and perhaps mid-tier) companies which together do, and will, contribute significantly to coal production. No other sector can boast such a vibrant junior industry as the coal industry. Why? The answer is simple: the need for energy, whether for local Eskom and high energy users’ consumption, or for export. The demand for coal is therefore supporting our large-scale companies, as well as our current and emerging juniors. How can this be when South Africa’s primary coal sources – the Witbank coal fields in particular – are reaching maturity, one might ask? The remaining coal pockets are ideally suited to the smaller players, which will find, secure and ensure that every last coal ‘ounce’ will be extracted and used viably. This is the role (largely) for the junior coal miner. Last month, I had the fortune to visit junior/ mid-tier coal company, Keaton Energy’s latest project, Vaalkrantz, which now falls under its project stable thanks to its acquisition of Leeuw Mining & Exploration. Situated in Vryheid, KwaZulu-Natal, Vaalkrantz is one of the few remaining coal mining operations in the area. Its current operational existence is thanks entirely to Keaton, which acquired the company as a distressed asset. The acquisition injected cash into the mine, brought on line an entirely new mining section, extended its life and subsequently saved 700 jobs. Of course the deal offered Keaton financial benefit as well; nonetheless, it is admirable and praiseworthy, especially considering Keaton’s cash injection into the asset prior to its official takeover. Looking at this story, we are clearly in exciting coal mining times, but indefinitely? A chat with the chairman for the South African Coal Road

Map steering committee, Ian Hall, who is also the regional head of strategy for Anglo American Thermal Coal, showed he is concerned about the long-term future of the coal sector. He believes that should the government’s plans to introduce renewable power sources and nuclear power stations into the energy mix succeed, the demand for coal will reduce. This is particularly critical now as substantial investment is required to develop new coal fields, like the Waterberg, for the immediate future. They require massive infrastructure spend and technologies that will enable the coal to be extracted and processed viably. Will coal companies invest as such if the demand for the product is reducing? A lot lies on how the energy programme will roll out. In 2010, the coal industry was responsible for 74 000 jobs; today, this number is probably much higher. I say this industry’s growth should not be compromised. I know it has a high carbon footprint, but the industry is working on that. Is the mining sector the only sector to blame when it comes to environmental hazard? At least it makes up for that by supplying a vital commodity, and it employs thousands of people directly and hundreds of thousands indirectly. And what is the future for the junior sector 30 or 40 years down the line? These are questions that need answers, not in 30 or 40 years’ time, but now. Laura Cornish

Inside Mining 04/2012

Mining news www.miningne.ws

Top mining stories headlining this month SOUTH AFRICA

Minister Molewa outlines progress on acid mine drainage Acid mine drainage

compiled by Ameerah Griffin

| SOUTH AFRICA | Shabangu vows to get tough on non-compliant mines Source: www.miningne.ws Despite the many advances in mining legislation, poor living conditions and general negligence of health issues are still evident in the country’s mines, Minister of Mineral Resources, Susan Shabangu, said recently. Speaking at an event to mark World Tuberculosis Day, Shabangu said that although there were improvements over the years, mine bosses needed to do more to control TB in their mines. Around 22 000 miners are said to be infected with TB across the country’s mines. “We need technologies to advance the lives and also improve the conditions of mine workers, and we also need to ensure research continues within the mining industry for us to develop best practices in our country,” Shabangu said.

stake in its Zimplats subsidiary to indigenous Zimbabweans in a deal that could ultimately see it claw back shares in the country’s largest platinum miner. Implats came under pressure to comply with Zimbabwe’s laws which state that foreignowned mining firms are to transfer 51% equity stakes to black Zimbabweans. Several of its proposals were rejected, leading to ultimatums from Youth Development, Indigenisation and Empowerment Minister, Saviour Kasukuwere. Implats and Kasukuwere said Implats’ latest proposal for its 87%-held subsidiary had been “accepted in principle” and the 51% would be sold for an independently determined “appropriate value”.

| AUSTRALIA | Australia passes controversial mining tax into law Source: www.bbc.co.uk

| ZIMBABWE | A compromise for Impala Platinum? Source: www.iafrica.com

Source: www.miningne.ws

Government will intensify its efforts to address the threat posed by acid mine drainage (AMD) in the Witwatersrand area, Water and Environmental Affairs Minister, Edna Molewa, said recently. Her statement comes after a panel of experts who were appointed to deal with the problem briefed her on the work that is being done to curb AMD. “The issue of AMD is one that government takes seriously and is committed to resolving. Even though the current government inherited the problem of AMD, we are intensifying our efforts and making noteworthy progress,” Molewa said. The Department of Water Affairs last year released a report regarding the AMD situation, which was compiled by a team of water and geology experts and presented to an Inter-Ministerial Committee on AMD in December 2011. The experts recommended that AMD intervention and management measures be undertaken ‘as a matter of urgency’ to avert crisis and stabilise the situation. including BHP Billiton, Rio Tinto and Xstrata. Strong demand for raw materials from China and India has led to a resource boom in Australia. The mining tax is aimed at distributing the benefits of that revenue to other segments of the economy. It comes into effect on 1 July. “This important reform will provide a revenue stream to ensure that businesses that are not in the fast lane of the resources boom get some tax relief,” Treasurer Wayne Swan told the country’s parliament recently.

| SOUTH AMERICA |

Impala Platinum (Implats) could be paid more than $US500 million (R3.8 billion) in a complex transaction to transfer a 51%

Inside Mining 04/2012

The Australian Senate has pushed through into law a 30% tax on iron ore and coal mining companies. The tax will raise A$10.6 billion (R84.6 billion) over three years from major companies

Peru’s gold output rises 13% in January on gains at Newmont mine Source: www.businessweek.com Peru’s gold output climbed to a six-month high in January on

gains at Newmont Mining’s Yanacocha mine, the government said recently. Gold production rose 13% to 15 116 kg, the Energy & Mines Ministry said in an e-mailed statement. Copper output fell 4.8% to 97 765 t, a nine- month low, on declines at mines operated by Freeport-McMoRan Copper & Gold and Xstrata. Zinc, tin, iron and molybdenum production all fell, while silver and lead gained.

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Cover story: opencast & earthmoving

THE TA400

Mining’s new rock solid performer Heavy equipment supplier Eqstra Construction Equipment, through its Terex distribution agreement, will soon launch a Generation 9 range of Terex articulated dump trucks (ADTs), which have been engineered to endure the toughest applications around the world. The largest machine in the range – the TA400 – is designed to deliver ‘unsurpassed’ performance to the opencast mining industry, writes Laura Cornish.

lthough the Generation 9 range is only due to be officially launched in June this year, Terex has a significant number of machines in stock and is ready to deliver to the first client who orders. “In comparison with the Terex Generation 7 range, the new machines easily demonstrate that they are not only more productive, but extremely fuel efficient,” says Eqstra Construction Equipment technical training manager, Martin Arthur. “They offer as much as a 12% reduction in overall fuel consumption.” According to Riaan Hoffmann, national sales manager for Eqstra Construction

Inside Mining 04/2012

Equipment, the machine’s launch falls in line with the company’s growth strategy: “To grow by supplying more machines to the mining industry.” “While our machines have always played a significant role in the mining industry, we believe our TA400 will offer major operational advantages to the sector. And these advantages will be realised from areas that we believe hold substantial business opportunities in the coal and iron ore industries, as well as along the copper belt in Zambia and the Democratic Republic of the Congo,” Hoffmann states. One of the company’s biggest supporters and machine owners is mining equipment

plant hire company, L&J Plant Services. “L&J was established in the 80s and has been providing heavy-duty mining machines into the opencast coal mining industry ever since,” says L&J MD, Johnny Gemmell. Its machines are located on four opencast coal mines as well as a quarry. Over the last three years, L&J has expanded its Terex fleet of equipment from two machines to 22. Although this BELOW The TA400 is the latest, most robust machine suited to the mining industry

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Cover story: opencast & earthmoving

does not include the new Generation TA400, its fleet does comprise older Generation TA400s. “The performance of Terex machines is excellent. They are simple to operate and maintain, and we like the combination of the Detroit engine, Allison transmission and ZF axles,” Gemmell continues. “I like the new TA400 machine and believe it will perform well in the industry. Terex always does its homework and I will consider this new range of ADTs when I expand my current fleet.”

What the TA400 has to offer: • Lower cost of ownership: The lower cost of ownership is a key feature of the Generation 9 ADTs. All models in the range benefit from oil-cooled multipledisc brakes on each axle, providing extended brake component life, reducing service intervals and

"The performance of Terex machines is excellent. They are simple to operate and maintain" Johnny Gemmell, L&J MD operating costs, and improving overall braking performance compared to traditional dry-disc brake systems, which are standard fitted on other leading manufacturers’ trucks. • The cab: The Terex cab is developed around the operator to improve comfort, efficiency and productivity. The new ergonomic cab has reduced interior noise

levels, more effective air conditioning, a high-quality sound system and even a new steering wheel and mirror arrangement. Interior aesthetics have also been updated to anthracite grey with a matte finish to reduce glare and improve durability. • The power: The powerful TA400 has a maximum payload of 38 t and a heaped capacity of 23.3 m³. It has a gross power of 331 kW, and with six forward gears, one reverse and a two speed drop box, the Generation 9 TA400 can travel up to

Inside Mining 04/2012

Cover story: opencast & earthmoving

After-sales service is an area of top priority for the company and something we are placing growing emphasis on 60 km/h. This makes it the ideal ADT for tough, heavy-duty mining applications. • The engine: The entire Generation 9 range is powered by Scania engines, which are renowned for high uptime and reliability, and underpinned by a worldwide service network. • Servicing: In an effort to reduce downtime, the service points on the Terex ADTs are designed for quick and easy access. The electronic-assisted hood raise and the fully tilting cab simplify access to major components and ground level service points, which further reduces downtime.

After sales service – a priority Eqstra Construction Equipment national operations manager, Stephen McMaster, says the company’s equipment strategy is strictly aligned with its after-sales service. “This is an area of top priority for the company and something we are placing growing emphasis on. The end user, who in our situation is largely mining clients, is demanding more efficiency from the OEMs, and we are catering to the demand.” According to McMaster, the after-sales service division looks after all parts servicing and supply, as well as technical

Inside Mining 04/2012

support (including training) from point of sales onwards. “We have adopted the Eqstra Group mining model and have all fast-moving parts (primarily) and technical support capabilities on site,” McMaster continues. To further cement its dedication to this particular business component, Eqstra provides its top 10 customers (which includes

L&J) with a dedicated product support representative, who is empowered to take decisions regarding equipment support without consultation. “We will focus on this aspect of the business with growing commitment and are bringing in the best, most qualified people to create a strong impact on the industry in terms of our dedication to- and after-sales service capabilities.” TOP The Eqstra team BELOW Johnny Gemel, L&J MD, owns a significant fleet of Terex machines and recently test drove the TA400

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Hot Seat

AURECON STRENGTHENS ITS RESOURCES FOCUS

Rallying clients and their projects In line with engineering, management and technical services group Aurecon’s client-centric business model, the company recently appointed Mark Berger as business development manager for the Resources Industry for South Africa, Africa and the Middle East, writes Laura Cornish.

y aspiration for Aurecon is to grow our Resources Industry client base on the back of strong business relationships and create the best value for our clients by delivering tailored business solutions,” says Berger. Berger has been involved in the minerals processing and materials handling sectors of the resources industry his entire working career. It is this knowledge, coupled with his strong existing relationships in the industry, that he will use to grow sustainable client relationships and build further brand awareness to supplement Aurecon’s existing experience and track record in this arena.

Inside Mining 04/2012

Individualised strategies for clients: “In addition to Aurecon’s strong technical expertise across the 11 industries in which it operates, what attracted me most is its client-centric, focused approach to client service. This sees large amounts of effort directed at our long-term client base and meeting their needs for both their existing and planned projects. This excites me as it enables us, through a cohesive, single-team approach, to develop individualised strategies for each of our clients, not just projects,” Berger explains.

“Exceptional” project delivery capacity: Berger believes that Aurecon’s past success in the resources industry is a result of

the company’s ‘exceptional project delivery capacity’. “Aurecon has a unique business proposition in that our clients benefit from our collaborative business model as it nurtures the development of market-leading expertise across all of our industries. Our technical professionals develop a business advantage for our clients based on a deep understanding of the industries in which they operate. This level of expertise and understanding is evident in the way

BELOW Khumani iron ore mine: Aurecon provided engineering services for both Phase 1 and Phase 2 of the Khumani Expansion Project in South Africa, including bulk earthworks

Hot Seat

ABOVE The KOV pit is a copper and cobalt open pit mine in Kolwezi in the DRC. In 2006, DRC Copper and Cobalt Project decided to re-open and continue operating the mine. To accomplish this, Aurecon designed a de-watering and desilting system; managed procurement of all equipment and services, as well as the supervision of equipment installation; and conducted the final testing and commissioning up to handover to the client

Aurecon meets the most challenging of delivery outcomes.” In this regard, Aurecon has delivered a range of solutions, from small start-up facilities through to major engineering, procurement and construction management (EPCM) projects, including bulk materials handling projects, mine, rail, seaboard import and export terminals, and associated port and marine facilities.

Growth targets Berger’s growth ambitions for Aurecon’s Resources Industry are based on cultivating a deep understanding of its clients' business and internal production targets. “We are also ramping up our ability to resource major projects in Africa by transferring our skills and experience gained from remote location mining in Australia to meet the market demand in Africa. The African continent, broadly speaking, is booming, and Berger has his attention focused specifically on bulk commodity countries like Mozambique and the Democratic Republic of the Congo (DRC) where new iron ore and coal projects are in massive abundance. “We will follow and accompany our clients into Africa and align our risk appetite with theirs.” Aurecon offers effective, integrated pitto-port material handling solutions, including a range of engineering services across the entire project life cycle, including master planning, feasibility studies, engineering design, construction management and operations and maintenance.

“I would like to extend this further to include minerals processing, in which I have extensive experience,” Berger notes.

All important alignment Aurecon will continue to align its business with that of its clients’ and business drivers. “Of increasing importance in this regard is safety,” comments Berger. “I have never seen such a people-orientated business with safety an intrinsic part of its DNA. We do not compromise on health and safety – it comes first in everything we do and is a core value for Aurecon. We foster this by appointing experienced teams that combine a deep understanding of the management of safety with the ability to align our approach to safety management with that of our clients.”

ABOVE Abbot Point Coal terminal: Since 2005, Aurecon Hatch has provided engineering, procurement and construction management services for three expansions of the terminal to 50 Mtpa and is also studying an ultimate expansion to 230 Mtpa

For the immediate future, Berger is excited about the prospect of working closely with Aurecon’s clients to ensure that they experience the best in dedicated client service. “It is only when we gain a thorough understanding of our clients’ businesses that we are able to effectively tailor our own business solutions to meet their needs. Aurecon intends on working hard to continually achieve this,” he concludes.

“I have never seen such a people-orientated business with safety an intrinsic part of its DNA” Mark Berger Substantial experience Berger holds a National Higher Diploma (Extractive Metallurgy) and an M Dip Tech (Metallurgical Engineering) from WITS Technikon. He has worked for a number of leading companies in the resources industry, including Mintek, Grinaker-LTA Process Engineering and Aveng E+PC Engineering & Projects Company (Formerly Grinaker–LTA Process Engineering). Berger brings years of experience in diverse roles to the company, including plant chemical engineer, senior process engineer, business development manager and business development director, among others, while his experience spans work on the: • Two Rivers platinum project, Lydenburg • Grootgeluk Medupi coal mine expansion project, Lephalale • Tarkwa carbon-in-leach expansion project, Ghana • Moma Sands expansion project, Mozambique • Kouilou potash project, DRC.

Inside Mining 04/2012

Hot topic

REFINING BRAND AND BUSINESS

Rand Refinery: aiming for another 90 years South Africa’s premier gold refinery, Rand Refinery, is proving that after 92 years of business, it can still evolve and adapt to changing market conditions and requirements – ensuring its business remains as successful for the next 90 years, CE Howard Craig, tells Laura Cornish.

and Refinery is the largest singlesite gold refining and smelting complex in the world. Since 1921, the organisation has refined more than 50 000 t of gold, nearly one third of all the gold ever mined in the world. It is also the only London Bullion Market Association (LBMA) accredited precious metals refinery and fabricator in Africa. Despite its ‘industry-leading’ position, the company is focused on diversifying and growing its business further, specifically by expanding into new regions, including Asia and Western Europe, as well as diversifying its current portfolio.

Inside Mining 04/2012

“Because the last 15 years have seen Rand Refinery successfully extend its footprint across the African continent, we will use this experience as an ideal launch pad to spread our footprint onto an international platform,” Craig points out. The company established a Singapore trading office in 2011 and has already sold about 100 t of gold to China, via London. Spreading its presence across the globe is only one tier of a much larger business strategy, however, Craig continues. Rand Refinery remains active with an initiative it refers to as ‘Walk Sure’. “It is about ensuring our business is sustainable in a

changing and evolving world, and prioritises the ongoing maintenance of old equipment and implementing new technologies where possible to enhance the refining and smelting operational efficiencies.” Part of this initiative has also seen Rand Refinery closely evaluate its energy consumption and efficiency – critical if it continues to expand its operations. “Even though our electricity consumption is a small component of our business, we view it as a priority and are reducing our footprint,” Craig discusses. Rand Refinery is rolling out an 18-month programme aimed at reducing its energy efficiency, which includes a power management

Hot topic

Did you know? • The refinery’s achievements have afforded it the distinction of being the only LBMAaccredited precious metals refinery and fabricator in Africa. • The refinery was appointed one of only five international LBMA referees, affording it the authority to adjudicate on metal content disputes between other refineries and their customers anywhere in the world. programme for employees. The programme will look at all opportunities of reducing energy consumption, including the installation energy-efficient light bulbs. Basil Read Energy, a wholly-owned subsidiary of construction major, Basil Read

• 50% of the gold Rand Refinery processes originates from mines outside of South Africa and Craig expects this statistic to increase even further to approximately 60%. • As part of a recent rebranding exercise, Rand Refinery has replaced its longstanding Springbok logo with an emblem representing a melting crucible. The new brand positioning centres around the core value of ‘pure refinement’, emphasising the

organisation’s heritage of quality products, craftsmanship and leading technical skills in the refinement process. Says Craig: “Even though our emblem has evolved, our DNA remains the same. Indeed, our partners and customers can expect improvements in quality and expertise, building on the heritage they’ve come to expect from our organisation over the past 90 years.”

Group, has undertaken a study for Rand Refinery to reduce its energy consumption. According to director, Ian Curry, the company has provided a variety of solutions (such as the light bulbs), which will enable Rand Refinery to increase its production

without further energy supply from Eskom. “We are also looking to move into value-add downstream beneficiation and have new circuits added to our smelter, which will specifically enable us to refine even lower grades of gold material.”

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