Inside Mining October November 2017

www.miningne.ws

AF R IC AN U PDATES ON TH E

Conflict-free tin for the DRC

G RO UN D A N D UN D E RG RO UN D

Nokeng: A new fluorspar flagship

The secret life of biomining

Sandvik

Sustainable, inclusive growth

Lonmin was and is a company with excellent assets. I was excited at the prospect of leading the team and contributing to making a positive difference after such a turbulent time; it was the perfect time to rebuild.” Ben Magara, CEO, Lonmin P8 ISSN 1999-8872 • R50.00 (incl. VAT) • Vol. 10 • No. 09 • October/November 2017

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CONTENTS

A F R I C A N U P DAT E S O N T H E G RO U N D A N D

U NDE RGROUND

REMSAFE MOBILE FIELD ISOLATION STATION

08 REGULARS 3

Ed’s Comment

7

Africa Round-up

39

Market News

MINERALS PROCESSING 18 Conscious energy 20 The secret life of biomining 23 Meeting demand – Metso expands foundry 24 Big data – A new crusade in mining

COVER STORY 4

MATERIALS HANDLING 26 The use of remote isolation systems in mining

Sustainable, inclusive growth

CEO TALK 8

PROJECTS Reopening an old mine

12

A new fluorspar flagship

14

Conflict-free tin for the DRC

COMMINUTION 32 Driving efficient energy use

16

ON THE COVER p4

MINE CLOSURE 34 Next-generation mine closure

LEGISLATION

www.miningne.ws

EVENTS 37 Investing in African Mining Indaba

Is Africa becoming uninvestable?

OCT/NOV

2017

PIPES, PUMPS & VALVES 30 Repairing pipe infrastructure

The Magara effect

10

14

This remote isolation system operates electrical and mechanical isolators simultaneously in just seconds.

The isolation is initiated in the field by the person doing the work, so no need for specialised electrician or fitter skills

AFR IC AN UPDATES ON THE

Conflict-free tin for the DRC

GROUND AND UNDERGROUND

Nokeng: A new fluorspar flagship

The secret life of biomining

Sandvik

Sustainable, inclusive growth

Lonmin was and is a company with excellent assets. I was excited at the prospect of leading the team and contributing to making a positive difference after such a turbulent time; it was the perfect time to rebuild.” Ben Magara, CEO, Lonmin P8 ISSN 1999-8872 • R50.00 (incl. VAT) • Vol. 10 • No. 09 • October/November 2017

25

32

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Endorsed by

Despite tough economic times and the uncertainty facing the industry, mining equipment and service provider Sandvik Mining and Rock Technology has responded to the market with optimism and poured further investment into South Africa

EDITOR'S COMMENT

Publisher Elizabeth Shorten Editor Mpinane Senkhane Journalist Phila Mzamo Head of design Beren Bauermeister Designer Ramon Chinian Chief sub-editor Tristan Snijders Sub-editor Morgan Carter Contributors Warren Beech, Jessica Black Livingston, Nicola Theunissen, Tony Stone Client services & production manager Antois-Leigh Botma Production coordinator Zenobia Daniels Financial manager Andrew Lobban Distribution manager Nomsa Masina Distribution coordinator Asha Pursotham

Leaving a legacy

F

OR THE MOST PART, the reality is that you can only mine certain resources in specific areas for so long. Eventually, with mining being a finite activity, miners pack up and move on. But the impact they’ve had lingers.

A recent data investigation of mine closures indicated that since at least

2011, no large coal mines operating in South Africa had been granted closure. What this really means is that the mines have closed illegally. As a result, they have not been rehabilitated and are simply abandoned, leaving a legacy of local and global pollution.

With the next and, presumably, final draft of the proposed changes to the NEMA Financial Provision Regulations expected to be published shortly, for the last round of public comment, the mining industry is essentially offered one more chance

Printers United Litho Johannesburg

to influence the amendments to the regulations before they are finalised. Thereafter,

Tel: +27 (0)11 402 0571 ___________________________________

the only recourse the industry will have will be in the courts.

Advertising Sales

Jenny Miller Tel: +27 (0)11 467 6223 jennymiller@lantic.net ___________________________________

Some stakeholders believe the regulations have the potential to be devastating to the mining industry, with increased liability and hiked closure costs that could drive smaller mining operations out of business.

South Africa has approximately 6 000 abandoned mines, which means that the industry, as a whole, needs to look beyond the risk and find a sustainable solution despite arguments against the regulations. There are opportunities to reduce liability and costs if the regulations are carefully considered and strategically implemented.

No. 9 3rd Avenue, Rivonia 2191

“Careful mine planning, with closure in mind, the clever

PO Box 92026, Norwood 2117

use of financial instruments to house rehabilitation funds

Tel: +27 (0)11 233 2600

and reasonable auditing can assist in reducing the

Fax: +27 (0)11 234 7274/5 www.3smedia.co.za ___________________________________

regulations,” says Garyn Rapson of Webber Wentzel.

Annual subscription:

In this issue

R330.00 (incl VAT & postage)

In this October/November issue of Inside Mining, we

Foreign: US$50

consider next-generation mine closure, looking at

Email: subs@3smedia.co.za

some foreign mine closure examples the NEMA aims to

ISSN 1999-8872 Inside Mining

encourage local operations to emulate. The Department

Copyright 2017. All rights reserved. ___________________________________

of Mineral Resources (DMR) has said it plans to prepare

All material in Inside Mining is copyright

as soon as they are finalised. The DMR also intends on

protected and may not be reproduced either

changing the perception that closure certificates are

in whole or in part without the prior written

never granted. The maturation of the one environmental

permission of the publisher. The views of

system and the finalisation of the amendments to the

contributors do not necessarily reflect those of the publishers.

EDITOR

rehabilitation liability, which is expected to surge under the

guidelines to assist in the interpretation of the regulations

regulations will assist government in processing closure certificate applications.

“The mining industry should really engage in this final consultation process to influence final changes that it would like to see made to the regulations. The deadline for compliance with the regulations for all existing holders of rights is looming – 19 February 2019 is just around the corner. If companies have not started work to comply,

To our avid readers, be sure to sign up and get the latest updates and inside scoops from the mining industry. Check out what we are talking about on our website and Facebook page, or follow us on Twitter and have your say.

we suggest that they do so urgently,” adds Rapson.

On this issue’s cover is mining equipment and service provider Sandvik Mining and Rock Technology, which has poured further investment into the South African market, demonstrating confidence despite tough times.

Optimism seems to be the order of the day, and even big data has found a solid space in minerals processing, which

@mining_news

can be read about on page 20.

Mpinane Senkhane

www.facebook.com/pages/ Mining-News

IN SID E M IN IN G OCT/NOV | 2017

3

COVER STORY

Sustainable, inclusive growth

Despite tough economic times and the uncertainty facing the industry, some mining participants have responded to the market with optimism – not just in theory, but in practice too. Among these is mining equipment and service provider Sandvik Mining and Rock Technology, which has poured further investment into South Africa.

T

HE MARKET IS unpredictable and

introduced the LH115L, a reliable and

robust, even with the recovery of

robust 5 t low-profile loader designed

Local operations, global standards

commodity prices; uncertainty

for demanding African conditions –

“During Sandvik’s 70-year history in

remains due to a number of

in particular, for use in narrow-reef

South Africa, we have become well

factors. However, optimism is the

orebodies, commonly found in

acquainted with the challenges

order of the day for Sandvik. Having

the South African chrome and

facing its mining industry and

serviced South Africa for 70 years now,

platinum sectors.

understand the important role

Sandvik has identified the opportunity

In doing so, the company has

that private investment and local

to further support local industry and

displayed its long-term commitment

manufacturing can play in extending

has decided to establish its own local

to the market.

mine life, skills development and

manufacturing facility for the complete production of the new Sandvik LH115L low-profile loader, launched for the African market.

The company officially opened the new R15 million production unit in Jet Park recently and is setting up local manufacturing capabilities to build high-quality load and haul equipment close to its customers. Sandvik

4

www.sandvik.com

INS I DE MI N I N G O C T / N OV | 2 0 1 7

employment,” says Simon Andrews,

The new LH115L loader has high availability and is easy to maintain, resulting in optimised lifetime operational costs

Vice President: Sales for Southern Africa.

In support of local industry – through the local manufacture of Sandvik products and localisation of machines – the company will be aiding both employment and local suppliers.

Some 67% of the machines’ materials will be sourced using local suppliers,

COVER STORY

locally sourced components and local employees.

In addition to the LH115L, Sandvik's Product Area Load and Haul is bringing its global standards and processes in high-quality manufacturing to the new facility.

The 1 500 m2 facility boasts an impressive 10 production bays, and employs 15 people, who were trained specifically to assist in the assembly of the LH115L LHDs – a first for the South African market.

“We are creating knowledge transfer to set up the proven processes and systems that we already have in our other manufacturing locations around the world, so that we can be in a position to add other Sandvik products to this manufacturing site when needed,” says Mats Eriksson, President: Product Area Load and Haul, Sandvik Mining and Rock Technology. The South African manufacturing facility began prototype operations in July 2017 and will initially produce LH115L machines. With this, Sandvik is bringing its global standards and processes in high-quality manufacturing to this new facility.

“This latest local manufacturing facility represents an exciting new chapter in the company's development and underscores our desire to play a part in skills development and local manufacturing capabilities,”

The LH115L The five-tonne LH115L low-profile loader is both cost-efficient and durable, and is the first product to be manufactured locally, using local suppliers, locally sourced components and local employees, with training programmes in place.

The new LH115L loader has high availability and is easy to maintain, resulting in optimised lifetime operational costs. In addition, Sandvik provides the full low-profile portfolio offering of underground drills and bolters to ensure matching sets of equipment.

The machine builds on the proven capabilities of its predecessor – the EJC115L – with the latest safety features, therefore easily complying with the latest safety requirements. With its powerful drivetrain, robust frame designed for low-profile operations and simplified electronics, the LH115L is optimised to provide high levels of availability and unequalled productivity in the harshest African conditions.

“Southern Africa makes up about 15% of Sandvik Mining and Rock Technology’s mining equipment sales worldwide, with 80% of our low-profile equipment sold into the South African and Zimbabwean markets,” states Björn Rosengren, CEO, Sandvik.

concludes Andrews.

Sandvik has launched its local manufacturing facility in Jet Park, near Johannesburg, for the complete production of the Sandvik LH115L

IN SID E M IN IN G OCT/NOV | 2017

5

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MINING NEWS

from around the continent

NIGERIA

SOUTH AFRICA

“I have endorsed all the recommendations of the parliamentary

Nigeria loses over N100 billion due to illegal mining

Mining industry in crisis – Baxter Speaking at the Africa Down Under

Williamson diamond mine contract,”

Nigeria’s Minister of Mines and Steel

Conference in Perth, Australia, Roger

Magufuli stated.

Development, Kayode Fayemi, has

Baxter, CEO, Chamber of Mines South

disclosed, in a meeting with staff in the

Africa, had three messages for investors.

ministry, that two firms involved in illegal

First, Baxter expressed the importance of

probe committees for the review of the

In a statement, Petra said its business was conducted in a transparent manner and it complied with all

mining – Solid Unit Limited and Geotess

mining in South Africa; however, he said

legislation in Tanzania, while a

Nigeria Limited – have extracted

the chamber and the industry had lost

parliamentary committee said there

minerals worth over N100 billion

confidence in Minister Mosebenzi Zwane

were “gross irregularities” in the manner

(R3.59 billion) in the past few years.

and his leadership of the Department of

in which the Tanzanian government

According to Fayemi, the two

Mineral Resources (DMR).

diluted its shareholding in Williamson

companies, which were shut down

“Significant corruption allegations

from an initial 50% to the current 25%.

In his televised broadcast, Magufuli

in Zurak, Plateau State, last month

against the minister and the DMR have

have deprived the country of

not been cleared. The industry does not

named three senior public officials

much-needed revenue.

believe that the approach adopted by

he had asked to resign. He also said

the DMR is serving the national interest of

he had ordered law enforcement

the country,” said Baxter

agencies to investigate allegations of

He added that the blacklisted companies had carried out “unwholesome” mining operations, which had led to environmental degradation and abandoned mine pits.

After the two companies were shut

Baxter added that the South African

under-declared diamond exports.

mining sector was, in fact, in crisis.

He noted that key governance and policy challenges in South Africa had

ZAMBIA

down, Minister Fayemi and National

eroded business and investor confidence.

Security Adviser (NSA) Babagana

In effect, he noted, policy and regulatory

Glencore reaches power deal

Monguno visited some illegal mining

uncertainty had frozen new investments

Glencore’s Zambian

sites in the richly endowed

in the sector.

Baxter did note there were

lead/zinc belt.

solutions to restoring the

A statement issued by

dream of a prosperous,

the ministry said, “The Federal Government

Roger Baxter, CEO, Chamber of Mines SA

has said that two alleged illegal mining

copper unit reached a deal to resume full power supply to its operations after President Edgar

growing and transformed

Lungu met with senior

mining sector.

company officials,

“To get mining back

according to his office.

President Edgar Lungu

companies – Solid Unit

on track requires policy

and Geotess Nigeria –

and regulatory certainty,

Corporation (CEC) will restore power

and government oversight

to Glencore’s Mopani Copper Mines

have illegally taken out minerals worth N100 billion in the past few years and that they have been operating illegally in

that recognises mining’s unique characteristics.”

He commended the industry for being resilient and stakeholders for trusting that

the area.

“Chairman of Solid Unit Usman

mutually agreeable solutions are possible.

Copperbelt Energy

and the two will conclude an agreement over a period of six weeks, the presidency said in an emailed statement.

The government will also resolve

Abubakar, who is regarded as the most

other outstanding issues with Mopani

notorious illegal miner in the state, has

regarding tax refunds and transfer

also been declared a wanted person by the NSA, who has ordered all security

TANZANIA

Petra contract review ordered

pricing over the same period, it said.

CEC lowered supply to Mopani

agencies to arrest him for acts seen

Tanzanian President John Magufuli has

after the company refused to pay

as economic sabotage,” the

ordered a review of a Petra Diamonds

new power prices introduced by the

ministry stated.

contract and asked senior public officials

government at the start of the year.

to resign over the outcome of a probe

Mopani said the fee increase wasn’t

into the mining sector,

part of its agreement with CEC and

Kayode Fayemi, Minister of Mines and Steel Development, Nigeria

The moves are the latest attempt

warned the dispute could affect

by Magufuli to tighten control over

4 700 jobs. The government has said it

the mining industry to boost

raised prices because it needs to pay

government revenues and stamp

for imports and electricity from

out alleged corruption.

private producers.

IN SID E M IN IN G OCT/NOV | 2017

7

CEO TALK

The Magara effect In July 2013, while the platinum industry was still reeling from the August 2012 events at Marikana, Ben Magara joined troubled miner Lonmin as its CEO – a bold move when market sentiments were at an all-time low. Under Magara’s leadership, however, the miner has since seen an incredible recovery. By Mpinane Senkhane

Ben Magara, CEO, Lonmin

Prior to Lonmin, Magara had enjoyed a successful career at Anglo American. Taking up the next challenge in his career, the Zimbabwean national was tasked with guiding the London-headquartered platinum miner's turnaround plan.

“Lonmin was and is a company with excellent

T

assets. I was excited at the prospect of leading the team and contributing to making a positive aking the reins of the most notorious

difference after such a turbulent time; it was

platinum miner in South Africa post Mari-

the perfect time to rebuild,” Magara asserts.

kana would have been the furthest thing from a dream job for even the most

And rebuild is exactly what Magara and the

opportunity Ben Magara embraced with open

Lonmin team did. The company turned an

arms and a sense of purpose. At the time, Lon-

underlying loss of $134 million in 2015 into

min was a landmine internally – everyone from

profits of $7 million in the 2016 financial year –

the unionised workers (those who had wanted

a staggering turnaround.

to strike and those who did not) to executives,

8

The turnaround

hardened mining executives, but it was an

These results came after what can be

management and shareholders had suffered a

labelled an incredibly turbulent year where

deep sense of tragedy.

the company cut more than 5 000 jobs and

INS I DE MI N I N G O C T / N OV | 2 0 1 7

CEO TALK

Some have

we have a robust business that we can

Lonmin’s capex

sustain in the long term,” says Magara.

plans, which are seen to be an under-investment of sorts and which critics point out could lead to production volatility and cost problems in the future.

Magara clarifies the company’s stance: initiated a $400 million rights issue.

the levers we are pulling to make sure that

questioned

This position, however, did not come without sacrifice; earlier this year, Lonmin was forced to retrench 6 000 employees.

“We managed to contain costs for the lasts three years , we managed to reduce high cost production and bring in profita-

“We want to spend only from cash

ble production. One of the ways we did

generated from our own activities or

this was sadly by retrenching 6 000 jobs;

third-party funding.

however, this was necessary to sustain the

“The underlying business is doing well,

business. We have had to make tough

of $355 million for the year ending

the operational business is pleasing and

decisions along the way,” he explains

30 September 2016, which was a major

that trajectory continues. Those are the

Lonmin made a pre-tax loss

improvement on a near $2.3 billion loss the previous year.

“Our liquidity has improved since

kind of factors we can control.”

Balance sheet recovery

Lonmin giving back More recently, Lonmin launched its Youth Month participation in June 2017 by host-

the rights issue from R422 million to

Lonmin has managed to recover its

ing 120 Grade 9 learners (15 from each

R447 million, so now there is enough

balance sheet to a certain extent, given

of the eight high schools in the GLC) and

leeway to manage the business,” he adds.

where the company was in 2015. By

eight beneficiaries of the 1608 Trust to a

slashing capital spending, the company

two-day workshop that is intended to give

refinancing costs and impairments, the

has been able to stabilise and start

young people insights, tools, career infor-

company has recovered and become

replenishing its coffers.

mation and guidance as they prepare

Stripping out one-off costs such as debt

profitable for the first time in years. Lonmin

“There are innovative ways to reduce

to go into their final stretch of high school

elected to reduce its platinum sales target

capex,” Magara states, adding that

and start thinking about the world of em-

by as much as 12% to 650 000 oz for its

Lonmin’s purchase of Anglo American

ployment or entrepreneurship.

2017 financial year in order to continue to

Platinum’s 42.5% stake in the Pandora

cut costs. Lonmin said it would increase

Joint Venture would defer between

teractions with young people in the com-

capex to R1.8 billion for its FY2017, com-

R2 billion and R3 billion in capex over the

munities in recent months, including dur-

pared to $1.26 billion in the year under

next five years.

ing demonstrations outside the company

review – itself a revised reduction of R1.5 billion.

“This acquisition alone brings synergies of R2.6 billion cash and these are just some of

The programme arose in response to in-

premises that took place last month by youth seeking employment opportunities.

“As we have sought to convey, job opportunities in platinum mining are limited due to the state of the PGMs market. However, it is our hope that this programme will supply current and future jobseekers and budding entrepreneurs with ideas about work opportunities and life skills inside and outside mining,” the company said in a statement.

“Lonmin is sensitive to the deprivation caused by unemployment in mining towns and rural areas of South Africa. We hope that this project, which is intended as a long-term initiative, will contribute to more people from these areas succeeding in improving their livelihoods,” Magara concludes.

IN SID E M IN IN G OCT/NOV | 2017

9

PROJECTS | SOUTH AFRICA

Reopening an old mine By all accounts, the old Prieska Copper Mine at Copperton has turned out to be a missed opportunity for Anglovaal, the mine’s first owners. For its intended new owners, the mine is turning out to be a particularly promising opportunity.

By Tony Stone

A

ustralia’s Orion Minerals, new

author Marc Ladewig, “Death breaks our

owner of the old Prieska

hearts, yet we reject its finality. There is a

Copper Mine at Copperton,

stubborn hope of continuance beyond

is elated with the prospects

mortality in the heart of humans that can-

of reopening the old mine, which was

not be extinguished no matter the im-

the first mine in South Africa to receive

pressive list of facts that seem to militate

an official certificate of closure.

against it,” are proving to be true in

At this very moment, drilling operations in and around the mine are yielding excellent

this old mine’s case.

A team drilling up into the mineral resource

On the map, it’s about 51 km south-west

ABOVE The Prieska Copper Mine in its heyday

been demolished and only a few of the 400 houses remain. As to the mine itself, it was stripped of its water piping and electrical cables, and anything of value was sold on the scrap metals market. The de-

results, confirming

of Prieska on the

struction is similar to a war-ravaged town.

that the future of

R357, in the vast

Nonetheless, what remains on the sur-

the mine looks

central Karoo

face, the 8.8 m diameter concrete-lined

decidedly rosy.

region of the

vertical shaft to 1 024 m (without head-

Northern Cape. In

gear), the three separate ramp declines

its heyday, it was

and tunnels to reach the 1 140 m deep

a copper and zinc

sulfide mineralisation, and the already

Anglovaal, once one of South Africa’s bigfour mining houses, produced more than 430 000 t of copper and 1 Mt of zinc at Prieska Copper

10

Where is Copperton?

TOP The reopened decline to the old Prieska Copper Mine, now used as the main entrance to the mine

mining town. From around 1970 to the nearend of century, the town housed between 3 000 and 4 000

in-place regional infrastructure will significantly reduce future development costs.

The old mine is recorded as one of world’s 30 largest volcanogenic massive

Mines from 1971 to 1996, when, at the

workers and their families. It provided a

sulfide (VMS) base metal ore deposits.

time, an uncertain economic outlook

school and excellent recreation facilities,

The unmined sulfide mineralisation has

and the high cost of capital influenced its

including a nine-hole golf course. Today,

been confirmed by extensive drilling

closure. However, it seems the words of

all but a few of the mine’s buildings have

and geophysics, which continues below

INS I DE MI N I N G O C T / N OV | 2 0 1 7

SOUTH AFRICA | PROJECTS the deepest stopes and thickens in the trough zone, up to 45 m in width. The ore bodies are open-ended with significant exploration potential to test extensions to the mineralised zone. There is a significant potential to define mineralisation up-dip in the western limb of the synform and along strike to the south-east, traversing on to neighbouring property.

Historical drill results Favouring the side of caution, Orion Minerals issued a cautionary statement to say that the potential quantity (tonnage) and grade of the exploration targets, exploration data to date, must be regarded as theoretical in nature and still need to be proved.

These exploration targets are based on exploration results from historical drilling intersections. It should be noted that at the mine’s closure (1996), the deep sulfide exploration target was included in the mine’s published resource inventory, as estimated under the supervision of Dr D Krige (the father of the Kriging resource estimation geostatistical method).

This inventory was classified using similar methodology to the JORC Code and adheres to some of the criteria for a historical resource and as defined in the ASX listing rules; however, Orion Minerals

Schematic of the mine and mineral deposits

has decided it is more appropriate to

In 2013, Agama Exploration & Mining, the

re-estimate the mineralisation using all available data.

Even so, incomplete archive records meant that the competent person be-

In search of gold current owners of 73.33% of the mine,

this is not substantial and, coupled with

drilled for gold with significant results.

infill drilling in key areas, represents a sub-

What they found was:

stantial opportunity for Orion.

• 50.4 m at 2.68 g/t gold from 8.1 m

lieved it is inappropriate to classify the

The exploration target is for an area

mineralisation as a mineral resource of

inscribed and tested by historic drilling.

any category subject to confirmation by

Substantial additional exploration upside

further drilling. If consistent with historical

remains untested by drilling both up-

exploration results, it may lead to the defi-

dip and long strike. Historic geophysical

nition of a mineral resource. The amount

anomalies/targets are recorded in these

of validation drilling required to ascertain

areas and are, as yet, untested.

(WC08) • 37.1 m at 2.72 g/t gold from 61.1 m (WC09) • 25.7 m at 2.72 g/t gold from 47.8 m (WC22) • 11.3 m at 3.36 g/t gold from 1.4 m (WC10) • 12.1 m at 2.37 g/t gold from 56.2 m

TABLE 1 Exploration targets based on exploration results from historical drilling intersections

(WC01) • 27.4 m at 2.18 g/t gold from 72.6 m

Exploration target

Tonnage

CU%

ZN%

+105

3.0 Mt to 4.5 Mt

1.0% to 1.6%

1.3% to 2.0%

It was concluded that the interpretation

Deep sulfide

7.0 Mt to 11.0 Mt

1.2% to 1.8%

3.9% to 5.9%

of drill results indicated a structurally com-

(WC01).

plicated body that justifies further invesThe old mine was stripped of its steel piping and ventilation channels

tigation. This is what Orion Minerals is currently doing with its drilling programme.

In the next issue of Inside Mining, we will look at this drilling programme and its results in more detail.

On-site, the Orion team members bubble with excitement at what they are finding. CEO Errol Smart says, “The zinc here carries no impurities such as cadmium etc., and it is free of lead. Then there is the gold.”

IN SID E M IN IN G OCT/NOV | 2017

11

PROJECTS | AFRICA

A new

fluorspar flagship Vision, resilience and faith in a dream have paid off. Nokeng Mine, a new R1.7 billion fluorspar open-pit site, is under development near Rust de Winter, north-east of Pretoria. By Tony Stone

W

ith its isometric crystal

adjacent, high-quality haematite-

formations, fluorspar –

fluorspar deposits – Plattekop,

composed of calcium

Outwash Fan and Wilton. The first

and fluorine (CaF2)

two, prioritised for development and

A beautiful, blue example of fluorspar, which comes in all colours of the rainbow

– is a rather obscure, yet important,

mining, contain an estimated total

Eskom power

industrial mineral used in a wide

mineral resource (Samrec-compliant)

Eskom has constructed a substation with

variety of chemical, metallurgical

of 11.46 Mt. Plattekop has 2.8 Mt

the associated powerline from the exist-

and ceramic processes. Some

at 42.4% CaF2 in-situ grade, and

ing Rust de Winter Substation to the new

Outwash Fan has 8.2 Mt at 24.6%

Nokeng Fluorspar Substation. This is ap-

CaF2 in-situ grade,” according to

proximately 15 km of 132 kV Kingbird line.

Rob Wagner, CEO of Sephaku Fluoride

The 2x40 MVA Nokeng Fluorspar Substa-

Limited (SepFluor).

tion takes up a space measuring 200 m by

crystals, cleaned and polished, become sought-after jewellery pieces.

“The Nokeng Mine comprises three

Environmental management

200 m, and an 8 m wide access road, in a 31 m wide servitude, has been construct-

The Environmental Management Pro-

ed. Within the substation area, a 36 m

gramme was prepared by Ria Pretorius

communication tower has also been con-

of Texture Environmental Consultants. In

structed. This has been carried out in com-

preparing the environmental impact as-

pliance with the National Environmental

sessment, ecologists, archaeologists, ar-

Management Act (No. 107 of 1998), read

chitects and historical architects, agricul-

with the Environmental Impact Assessment

tural specialists, geotechnical engineers,

Regulations, 2010 (GNR 543 of 2010), and

geohydrologists, civil and electrical en-

includes applicable activities as listed in

gineers, social consultants, landscapers,

GNR 544 and GNR 546 of 2010.

and contractors were consulted.

Bokeng’s production capacity The current estimated life of mine is

Rob Wagner, CEO, Sephaku Fluoride Limited

12

INS I DE MI N I N G O C T / N OV | 2 0 1 7

19 years. At an average ROM rate of

AFRICA | PROJECTS

TABLE 1 General physical properties of fluorite CHEMICAL CLASSIFICATION Colour

Typically purple, green and yellow; also colourless, blue, red and black

Streak

White

Luster

Vitreous

Diaphaneity

Transparent to translucent

Cleavage

Four directions of perfect cleavage

Mohs hardness

4p

Specific gravity

3.2

Diagnostic properties

Cleavage, hardness, specific gravity, colour

Chemical composition

CaF2

Crystal system

Isometric

Uses

• Numerous uses in the metallurgical, ceramics, and chemical industries • A source of fluorine, hydrofluoric acid, metallurgical flux • High-clarity pieces are used to make lenses for microscopes, telescopes and cameras

Left to right: Dr Lelau Mohuba (chairman), Rob Wagner (CEO), Rose Matjiu (manager: Social Development) and Johan Brits (project director) of Sephaku Fluoride Limited

fluorochemical initiative in the country,” says Wagner.

Market demand Acid-grade fluorspar, which is in great demand by the chemical and aluminium industries, must contain at least 97.5% CaF2, with not more than 1.5% SiO2 and 0.5% Fe2O3. Often, the silica is limited to

1.2%, with penalties starting at 1.0% SiO2.

These limitations on grade and impurities require extremely close mill control, par-

ticularly through flotation where selectivity and high recovery are essential.

South Africa and surrounds currently Workers logging drill samples

Fluorspar crystals on a rock

consume some 30 000 tpa of aluminium tri-fluoride, all of which is imported. The demand for hydrogen fluoride in South Africa is estimated to grow by some 38 000 tpa in

600 000 tpa, production rates between

Sub-A flotation tank concentrator. The

130 000 tpa and 185 000 tpa of acid-

rough concentrate is fed into a second set

grade fluorspar for beneficiation

of concentrator tanks and processed. A

duction of acid-grade calcium fluoride

at SepFluor’s planned Ekandustria

return pipe takes cleaner primary tailings

will be delivered to a hydrogen fluoride

fluorochemical plant and up to 30 000 tpa

back to the conditioner, with final tailings

manufacturing facility, which will produce

of metallurgical-grade fluorspar (for local

moved to waste. Concentrate is pumped

high-grade anhydrous hydrogen fluoride

and export steel markets) are targeted –

to the thickener tank, filtered and dried

primarily for use in an aluminium tri-fluo-

through surface and open-pit mining.

in a standard fluorspar dryer, then screw-

ride manufacturing facility. This facility will

conveyed to steel storage tanks before

produce aluminium tri-fluoride for use in

being transported to market.

both local and international aluminium

The acid-grade beneficiation process

Fluorspar ores can be quite complex,

the short to medium term.

“It is envisaged that Nokeng’s pro-

smelters. The hydrogen fluoride facility will

The entire fluorochemical process begins

particularly when lead and zinc sulfides,

with the ore being fed into a coarse-ore

barite, calcite, iron oxide and siliceous

the building and construction industries,

bin. From here, it feeds through to a jaw

impurities are involved. It is for this reason

and in fertiliser applications, while the

crusher to break the ore down for further

that laboratory flotation tests should be

excess hydrogen fluoride not used for the

processing. The ore is transported via

carried out before finalising a process

production of aluminium tri-fluoride will be

conveyor to a fine-ore bin and stored

flow flowsheet.

available for downstream fluorochemical

there. From the fine-ore bin, the ore is fed

“The fluorochemical plant, scheduled

also produce anhydrite (CaSO4) for use in

initiatives,” Wagner adds.

via an adjustable-stroke belt ore feeder

to come on stream simultaneously with

into a ball mill, where it is crushed into

the mining operations, is being promot-

Social and labour plan

a powder form. From the ball mill, the

ed against the background of growing

The mine is 34.8% owned by BBBEE partner

powder is fed into a crossflow classifier

demand throughout Southern Africa for

Ixowise and has a social and labour plan

and on to a mixing tank where reagents

fluorochemical products, together with

committing some R26 million. Nokeng is

and flotation conditioners are added to

the South African government’s sup-

expected to create ±300 fixed-term jobs

the agitated water/ore mix. From here,

port for the downsteam beneficiation

during construction and ±200 permanent

the liquid mix is pumped to an agitated

of minerals and the development of a

jobs thereafter.

IN SID E M IN IN G OCT/NOV | 2017

13

PROJECTS | AFRICA

Conflict-free tin for the DRC spaced 20 m apart vertically. Getting

The beginning of 2019 is expected to see the first production of conflict-free tin concentrate at Alphamin Bisie Tin Mine. Phila Mzamo looks at the stakeholders' journey thus far.

growth. It contributes significantly to benefit

the box cut in time was an extraordinary

the community by creating employment

achievement for us. Currently, we are

and facilitating the development of

putting together the set frame that will

supportive infrastructure in North Kivu,”

protect the miners going underground.”

says Kitakya.

“Already, Alphamin’s positive impact is leading to vastly improved governance, security, safety, increased economic

He explains that the balance of the Bisie operation will focus on infrastructure, specifically sorting out the access road.

“We’ve put in roughly 35 km of access

activity and the building of Luuka Primary

roads largely by hand, where the initial

School and Logu-walikale.” Kitaya adds

clearing and alignment of the road was

that 115 development projects will also

also done by hand. We’ll also be putting

P

be partially financed by a percentage of

in the wearing profile and sorting out the

ABM’s operational expenses.

water drainage profile,” says Kamstra.

Mine (ABM) is on track to deliver

Construction and infrastructure

Production

on its commitment to develop

Boris Kamstra, CEO of Alphamin, explains

According to Kamstra, the Mineral

the first large commercial tin mine

that the project’s progress is on track as

Resource estimates for Bisie were updated

in the eastern DRC. The project plans to

construction activities commenced in

in May 2016 indicating tin mineral resource

produce responsible, developmental,

Q1 2017. Development is about to enter

estimates of 19 600 t in Measured Mineral

conflict-free tin concentrate, while bringing

the underground construction phase of the

Resource, 188 400 t in Indicated Mineral

substantial benefit to local communities

industrial mine, which will allow

and attractive returns for investors. North

for the first production of

Kivu’s Minister of Mines, Professor Anselme

tin concentrate to take

Kitakya, has expressed his support for the

place during the first

Bisie Tin Project and the value that the pro-

half of 2019.

roduction at Alphamin Bisie Tin

ject already brings to the Walikale territory –

“Our critical

Resource and 22 800 t in Inferred Mineral Resources declared at a 0.5% tin cut-off grade.

The tin mine’s activities are

the poorest area in North Kivu, about 60 km

development path

from where the mine is located.

has been for the

double the DRC’s

underground mine

exports of tin,

“Alphamin, with its Bisie Tin Mine Project, is already a catalyst for regional economic

with sublevel caving

expected to

as it is expected to produce approximately 9 900 t of low-cost, conflictfree tin concentrate per annum for at least 12 years.

However, the view is that the life of mine will be significantly longer as the drilling undertaken to date comfortably supports 12 years at least, adds Kamstra.

The CEO states that the Bisie tin deposit is one of the largest and most significant in the world and the ABM is among the most advanced tin projects being developed; thus, it presents significant advantages.

He adds that tin mineralisation at Bisie is unique due to its high-grade nature. “The

14

INS I DE MI N I N G O C T / N OV | 2 0 1 7

“It’s important for the country to double its tin production to benefit not only the region, but the country as a whole.”

Boris Kamstra, CEO, Alphamin

project has excellent metallurgical recovery characteristics and very low levels of deleterious materials in concentrate. It is expected to produce tin concentrate at an all-in operating cost of US$8 316 per tonne after it comes into production. The project is anticipated to reach steady state production towards the end of 2019,” explains Kamstra.

Materials handling According to Alphamin, blasted ore will be loaded by 14 t capacity, rubber-tyre, load haul dump units, dumped into 40 t articulated dump trucks and hauled to the surface where it will be stockpiled ahead of processing for tin recovery. Mining is planned at a rate of 360 000 tpa. The orebody will be accessed via a trucking ramp located 20 m below the orebody. The trucking ramp has been designed as a 5 m x 5 m excavation and will be developed at an inclination of 9 degrees below the horizontal. The trucking ramp will serve as the main intake airway for the mine.

“In the initial phases of the mine, we will generate a >60% tin concentrate and ship it from the mine to Goma, the provincial capital of the North Kivu Province, where the traders will take it off our hands and deliver it to the relevant smelters,” explains Kamstra. “It is our dream that, in time, we will be able to put up a smelter, probably in the Walikale area. Provision for hydro sites and power for a smelter will be the main issue.

“Our mine currently has a very low power requirement and, as such, the economics of a hydro site don’t necessarily work very well; neither does the timing, and right now, we do not have the luxury of putting in a hydro scheme.”

According to the company, because of the rough terrain where the mine is located, the company has had to work closely with government to secure the tin ore using military troops, and transport it using military-specification 6x6 and 8x8 vehicles.

Overcoming challenges A large part of the mining activity’s success relies on the security of the mine, as the region has a large concentration of armed militia groups and illegal mining activity. The DRC government has been supportive and deployed a strong military presence in the camp to protect the miner’s assets. “We have a military curtain between ourselves and the east of us, which is largely unpopulated forest,” says Kamstra.

There are also as many as 800 artisanal miners in the area and Alphamin is working with the government to move them to legal sites where small-scale mining is allowed. Following his site visit, Minister Kitakya said the visit of the commission served to reinforce the government’s serious approach and its desire to sensitively restore order to the situation.

LEGISLATION

Are we

becoming uninvestable?

F

irst off, positive views of investment in Africa don’t always extend to the mining and natural resources sector. While it is often

acknowledged by stakeholders that the mining and natural resources of a

Within the context of a mostly positive view of investment in Africa, why is the question posed whether the African mining and natural resources sector is becoming uninvestable?

By Warren Beech and Jessica Black Livingston

country can contribute meaningfully to growth, development and transforma-

(equity and bond markets that are

tion, there is a growing questioning of the

typically smaller than emerging mar-

impact of mining on aspects such as the

kets and where there is less liquidity)

environment, host communities, social

and investment instability in emerging

structures, tourism, and industries such as

markets such as South Africa, the re-

these disputes to arbitration. None of this

agriculture, versus the benefits that often

cent events in these two countries are

is good for the Tanzanian mining sector.

flow from mining and beneficiation oper-

more concerning.

Local conditions

ations. As the voices of concern increase

Tanzania’s president, John Magufuli,

and develop, the benefits that flow from

signed into law the Natural Wealth and

Recently, the South African Minister of

mining and beneficiation operations are

Resources Bill 2017, and the Natural

Mineral Resources, Mosebenzi Zwane,

likely to be questioned even further.

Wealth and Resources Contracts Bill

published the ‘Reviewed Broad-Based

2017, on 3 July 2017. These laws, which

Black Economic Empowerment Charter

regulatory changes in Tanzania and

were fast-tracked though Tanzanian

for the South African Mining and Minerals

South Africa have brought into sharp

Parliament in a matter of weeks, have

Industry, 2016’ (also known as Mining

focus the fragility of investment decisions

far-reaching consequences for foreign

Charter 3). The response was immediate,

relating to so-called frontier markets such

companies with investments in Tanza-

dramatic and far-reaching. It is estimated

as Tanzania, and emerging markets such

nia. Tanzania is one of Africa’s largest

that mining stocks lost approximately R50

as South Africa. With a decrease in the

gold producers (depending on the

billion in value following the announce-

number of investable frontier markets

figures used, Tanzania is either the third

ment, with the rand losing ground and

Second, the recent mining policy and

or fourth largest gold

the Chamber of Mines, which represents

producer in Africa).

the majority of the mining companies,

The uncertainties flowing from the new laws are likely to impact quite dramatically on junior mining companies, which are focused on exploration, and they will make cap-

The mining sector remains a substantial contributor to the GDP of many African countries

INS I DE MI N I N G O C T / N OV | 2 0 1 7

launching legal proceedings against Minister Zwane. The grounds of challenge go to the heart of the minister’s powers and functions under the mining legislation and the constitutionality of Mining Charter 3.

While Minister Zwane has labelled the

ital-raising exercises extremely difficult,

legal challenge as being anti-transfor-

if not impossible. Putting the ownership

mation, the Chamber of Mines and other

of mining assets in a company at risk

bodies representing mining interests have

is likely to scare off would-be investors

consistently expressed the position that

and make existing investors exercise

the industry is committed to transfor-

extreme caution.

mation and that it has demonstrated its

While multinational mining companies

16

Warren Beech, global head: Mining Subsector at Hogan Lovells in Johannesburg

commitment through the implementation

with investments in Tanzania continue

of appropriate programmes of transfor-

to engage with the Tanzanian govern-

mation (including in respect of the host

ment, some have declared disputes

communities through the social and la-

with the government and are referring

bour plans that are a requirement under

LEGISLATION the Mining Laws). The industry maintains

rights, renewals of prospecting and

that the targets in the Mining Charter

mining rights, and ministerial consents in

must be achievable and sustainable,

terms of Section 11 of the Mineral and

and that the timeframe should take into

Petroleum Resources Development Act

account the reality the mining industry

(No. 28 of 2002; the MPRDA) (in summary:

finds itself in, with the spectre of signifi-

where a right or an interest in a right is

cant, further job losses in the near future.

to be transferred or there is a change of

(While figures vary, the suggestion is that

control, ministerial consent is required).

in excess of 80 000 direct jobs have been

The minister indicated his intention to

lost in the industry over the last three to

issue the moratorium notice under Sec-

five years. Various South African mining

tion 49 of the MPRDA, which vests the

companies have recently announced

minister with the authority to issue a no-

proposals for further job losses, which

tice prohibiting prospecting or mining in

may exceed 20 000 direct jobs.)

respect of certain geographical areas or

There were glimmers of hope when, fol-

The investability of Africa is likely to depend significantly on balancing the growing need for mineral resources and addressing concerns that multinational companies extract value without returning benefits for host countries

certain minerals for a particular period,

Africa has a significant and often thriving

lowing negotiations between the Cham-

having regard to the national interest,

mining and minerals industry, providing

ber of Mines and the ministry, Minister

the strategic nature of the mineral in

millions of jobs and opportunities. It is

Zwane agreed to suspend Mining Char-

question, and the need to promote the

also a source of significant foreign di-

ter 3 pending the outcome of the legal

sustainable development of the nation’s

rect investment, and the mining sector

challenge initiated by the Chamber.

mineral resources.

remains a substantial contributor to the

The widely expressed view was that the

GDP of many African countries, with the

Zwane published his intention to issue a

minister had exceeded his powers under

benefits that this brings to the growth of

notice placing a moratorium on all appli-

Section 49 of the MPRDA by intending to

those economies. It is likely that demand

cations for new prospecting and mining

issue a blanket notice.

for certain precious metals will continue

However, the following week, Minister

On a positive note, stakeholders across

so-called battery metals will grow expo-

recognised trade unions in the mining

nentially. All of this creates opportunities

industry, have spoken out against the

for investors, provided they have a prop-

actions of Minister Zwane and there have

er understanding of the various risks in-

been widespread calls for his resignation

herent in these investment opportunities.

or sacking. But this, of course, does not

The investability of Africa is likely to de-

remedy the turmoil the South African

pend significantly on balancing the grow-

Mining sector finds itself in, and large-

ing need for mineral resources while, at

scale job losses loom.

the same time, addressing concerns that multinational companies extract value

Africa not uninvestable Jessica Black Livingston, deputy: Mining Subsector at Hogan Lovells in Denver, USA

to grow, and that the demand for the

the spectrum, including the largest

without returning benefits for the host

While the South African and Tanzanian

countries, and ensuring that the vast so-

mining sectors are in turmoil, this does

cio-economic benefits that can flow from

not mean that Africa is uninvestable.

mining operations materialise.

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T

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18

INS I DE MI N I N G O C T / N OV | 2 0 1 7

products it uses, focusing on quality and not just price. Upgrading to Shell Omala S4 GX oil for all gearboxes, including the

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IN SID E M IN IN G OCT/NOV | 2017

19

MINERALS PROCESSING

The secret life of biomining NASA, in solving the challenges of space travel, has invented and matured a number of amazing technologies. In the pursuit of mining planets, it, along with university researchers, has made some fascinating discoveries. By Tony Stone

T

The NASA-sponsored research team on its way to discovering the devil’s worm (Halicephalobus mephisto) in the depths of the Beatrix Gold Mine back in 2015 (Photo: Tony Stone)

wo years have passed since we

at the same depths. NASA’s interest in

rock and excreting gold, which was

reported the 2015 discovery of

bugs deep below the earth’s surface

incorrect. As it turns out, it’s been

the 0.5 mm long devil’s worm

is quite simple: it wants to know what

found that various bacteria, some

(Halicephalobus mephisto) in

we would find if we started mining on

of which are consumed the devil’s

the terrestrial depths of the Beatrix

Mars or any other planet. Also, what

worm, owe their survival to their

Gold Mine, 1.3 km below the earth’s

effect will alien life have on these life

natural Midas touch. Roy Choudhury,

surface. Nematodes were not known to

forms and, more importantly, as a

at India’s Institute of Microbial

live beyond tens of metres deep. Only

consequence, what effect will these

Technology in Chandigarh, has found

microbes were known to exist beyond

life forms have on the aliens – us,

more than 15 species capable of

a kilometre underground. At the same

people from earth.

producing gold nanoparticles.

time, Professor Tullis Onstott of Princeton

As South Africa has the deepest mines

Nathan Magarvey of McMaster

University and his team found Plectus

in the world, this was the obvious place

University in Hamilton, Ontario,

aquatilis, a previously known roundworm,

to start the research.

discovered that Delftia

These minute worms – the deepest-

acidovorans lives in sticky biofilms

living multicellular animals ever found

that form on top of gold deposits, but

– live in groundwater that is 3 000 to

exposure to dissolved gold ions can kill

12 000 years old. They are able to

it. This is because, while metallic gold

withstand heat, crushing pressure

is unreactive, the ions are toxic. To

and waters with an almost absent level

protect itself, the bacterium evolved

of oxygen.

a chemical that detoxifies gold ions

International research Since Onstott’s discovery, much has been learned about these organisms,

by turning them into harmless gold nanoparticles. These accumulate safely outside the bacterial cells.

Frank Reith, of the University of

and their food source. It was initially

Adelaide in Australia, discovered that

thought that H. mephisto was eating

another species, Cupriavidus metallidurans, survives using the slightly riskier strategy of changing

The devil’s worm, scientifically referred to as Halicephalobus mephisto (Image: Tullis Onstott)

20

INS I DE MI N I N G O C T / N OV | 2 0 1 7

gold ions into gold inside its cells, then excreting these gold nuggets.

Professor Tullis Onstott fitting the tailor-made sampling dispenser to the borehole release valve that accesses a large water fissure in a remote part of the Beatrix Gold Mine (Photo: Tony Stone)

If we can build cavernous workshops like this underground, we can also build mineral processing plants here (Photo: AHK Canada)

existing processes that operate in an aerobic environment (on the

Nanoparticles of bacterium-produced 24 carat gold

surface) are unsuitable for taking advantage of the bacteria

and recycled or residual materials uses

discovered by Onstott, Choudhury,

microorganisms in one or more stages of

The official definition of biomining is

Magarvey, Reith et al., as these exist

a process. The most exciting advances in

“the process of extracting valuable

in an anaerobic environment at

biohydrometallurgy are occurring in the

metals from ores and mine tailings with

depths, in darkness and under crushing

field of microbiology.

the assistance of microorganisms”. For

pressure, without any agitation of the

example, gold finely disseminated in

fissure water.

Use in mineral processing

sulfide ores reduces the capacity of

The question is just how viable is

As Helen Watling, of the Commonwealth Scientific and Industrial Research Organisation in Melbourne,

conventional cyanidation to recover

anaerobic biomining on a large

Australia, says, “The body of knowledge

gold. By either grinding the ore to a

commercial basis? Where will the

being acquired through the application

very fine powder and/or using bacteria

mineral processing take place, given

of molecular biology methods and

in an aerated stirred-tank reactor to

the metabolic needs of the bacterium

techniques will be used increasingly to

break down the sulfide minerals by

deep in the mines? Is it an effective

monitor microbial behaviour, optimise

oxidative dissolution, thereby dissolving

and green technology to mine gold?

conditions for more appropriate

ferrous iron (Fe2+), the gold is exposed

The answers to these questions can

microbiological activity, and/or infer the

to the cyanide solution. Bio-oxidation

in part be answered by the fact that

microbiological health of bioreactors

has proved to be a cost-effective

South Africa’s gold ore grades have

(tanks). But, as we have identified, deep-

and efficient way to extract gold from

been steadily declining. Over that last

mine bacteria are totally outside the

sulfide ores.

12 years, ore grades have declined

current body of knowledge and much

But, what has been established

by approximately 44%, according to

work needs to be done.

is that biomining is constrained to

the Chamber of Mines South Africa.

conditions where microorganisms are

Declining ore grades means that

of the University of the Free State’s

metabolically active. This means the

production costs will continue to rise.

research team in the Department

With necessity being the mother of

of Microbial, Biochemical and Food

all invention, there is no doubt that a

Biotechnology that assisted Onstott

solution will be found.

and his team – says, “In our wildest

The most exciting advances in biohydrometallurgy are occurring in the field of microbiology

That solution may come from

Professor Esta van Heerden – leader

dreams, we could not have imagined

biohydrometallurgy, a subdivision of

that we would get so much of a

hydrometallurgy where the use of

reaction from our discovery.”

aqueous chemistry for the recovery of metals from ores, concentrates

As much as it has been a major discovery, the real work begins now.

IN SID E M IN IN G OCT/NOV | 2017

21

www.schneider-electric.co.za

MINERALS PROCESSING

ISITHEBE FOUNDRY INVESTMENT

Meeting demand

Metso expands foundry Metso has invested approximately R55 million (€3.5 million) in crusher wear parts manufacturing in Africa to meet growing demand from the mining industry.

T

he capital will be invested

any other crusher on the market, fulfils the

agenda to execute our commitment to

into the global industrial

volume demand by efficiently crushing

ensuring availability and reduced lead

manufacturer’s Isithebe Foundry

large quantities in one machine. It was in-

times for our customers,” says Jose Perez,

in KwaZulu-Natal, 150 km from

troduced to the market in late 2014, and

senior vice-president of the Crushing and

Durban. The project expansion will

commissioned at First Quantum Minerals’

Screening Wears business line at Metso.

increase its manufacturing capacity for

Sentinel mine, Zambia, in 2015.

large crusher wear parts castings used

The first product deliveries from the new

Sustainable foundry operations

in minerals processing by investing in a

furnace are scheduled for May 2019.

The new foundry will be built according

second melting furnace.

During the renovation project, produc-

to strict sustainability and quality prin-

tion of castings will continue as usual in

ciples in line with Metso’s international

the existing production lines.

focus on sustainability best practice, says

The investment has a global reach, as it would ensure the availability of Metso’s heavy crusher wear parts across the world. “The demand for large crusher wear parts is growing in the mining in-

The investment should also spur enhanced economic activity in the region.

“We are the leading service partner

Thando Makhoba, director of the Isithebe foundry. “Sustainability is of the utmost importance to Metso. We are developing

dustry. With this investment, we ensure

for the mining industry, and the only

our operations in a safe and sustainable

we can meet our customers’ needs.

supplier able to provide a full portfolio

manner, in close dialogue with local

Through the renewal of the foundry,

for comminution, from spare and wear

communities,” says Makhoba.

we will improve our capabilities to deliver

parts to equipment and service. This

high-quality heavy wear parts,”

investment is part of our development

The Isithebe plant is part of Metso’s global foundry network, consisting of

says Joni Meronen, director: Mining

foundries located in Ahmedabad, India;

Crusher Wears, Metso.

Prerov, Czech Republic; Quzhou,

Parts for world’s largest cone crusher The renewed foundry will be able to manufacture wear parts for the Nordberg MP2500 cone crusher, as well as for Metso and third-party primary gyratory wear parts, with full use of the latest manufacturing technologies.

As ore grades in the industry decline, more processed ore is required to meet production demands. The MP2500, known as the world’s largest cone crusher and claiming to process more ore than

More about Metso • Products range from mining and aggregates processing equipment and systems to industrial valves and controls • Customers are supported by a broad scope of services and a global network of over 80 service centres and 6 000 services professionals • Metso is listed on Nasdaq Helsinki and had sales of about €2.6 billion in 2016.

The company employs 11 000 people in over 50 countries

China; and Sorocaba, Brazil.

“Metso is a world-leading industrial company serving the mining, aggregates, recycling, oil, gas, pulp, paper and process industries. We help our customers improve their operational efficiency, reduce risks and increase profitability by using our unique knowledge, experienced staff and innovative solutions to build new, sustainable ways of growing together.

The refurbishments to the Isithebe Foundry will play an integral role in supporting Metso to achieve this mandate in South Africa,” Makhoba concludes.

IN SID E M IN IN G OCT/NOV | 2017

23

MINERALS PROCESSING

Big data

A new crusade in mining The mining industry is witnessing growing evidence of how the endless amount of big data captured in exploration and operations could bring about the next wave of innovation.

By Nicola Theunissen

D

uring a mining forum on

especially relating to human behav-

additional context and insight to ena-

technology in Las Vegas

iour and interactions. Big data floods

ble better decision-making. In addition,

three years ago, Tony O’Neill,

any business corporation on a daily

big data scales in a predictable and

group director: Technical and

basis. However, experts say it’s not

straightforward way, both in size and

Sustainability, Anglo American, said,

the amount that’s important, but

speed, so that business analytics report-

“For the first time in my 36-year career

rather what organisations do with it.

ing solutions can grow with your busi-

in mining, I feel we’re on the cusp of an

Across various industries, big data is

ness,” says ABB. In the mining industry,

explosion of game-changing technol-

increasingly being used for insights that

the applications of big data are man-

ogy.” O’Neill highlighted rock-cutting

lead to better business decisions and

ifold. One case in point is in the use of

lasers, medical imaging for real-time

strategic operational development.

big data for new geological discoveries.

technologies as “low-hanging fruit just

Did we miss something?

Exploring unmined assets

of the Witwatersrand’s School of

within our grasp”.

sampling, 3D printing and big data as the key influencers. He described these

Professor Susan Webb of the University Geosciences was recently quoted in

According to ABB, raw data is useless

the media explaining how decades of

Big data is comprised of massive

unless it is turned into knowledge: “Data

big data could be used for new mineral

datasets that can be analysed to re-

needs to be analysed and applied am-

discoveries, both in precious and base

veal patterns, trends and associations,

bitiously and innovatively – to the benefit

metals. She said it could bring about

of decision-makers, the individual indus-

the revival of struggling sectors such as

try and the whole network. The answer

gold mining. In Australia, a data mining

is software-based analytics and decision

initiative by Sydney University’s School

tools suited for industrial operations.”

of Geosciences explored new methods

According to the technology leader,

to target unidentified/previously

previous business intelligence solutions

unmined mineral deposits. The initiative

focused mostly on internal structured

harnessed Geoscience Australia’s rich

data and processed the information

datasets to combine and analyse a

in regularly occurring cycles. “Big data

vast amount of disparate information

expands your view of the enterprise by

to realise the datasets’ full potential.

increasing the range and variety of data

Many experts believe the use of big

that can be analysed, so that you have

data in geology to be revolutionary for new discoveries.

Until recently, scientists did not

Tony O’Neill, group director: Technical and Sustainability, Anglo American

24

INS I DE MI N I N G O C T / N OV | 2 0 1 7

have the necessary modelling and visualisation techniques to capitalise

MINERALS PROCESSING

The key to taking the right mining decisions is the availability of accurate data

on massive stockpiles of geo data, says

optimisation,

that determine

Science Daily in an article titled ‘Big

safety and

drill holes. The key

data points humanity to new minerals,

human resources.

new deposits’. New innovations in

A recent survey

network analysis now enable earth

by Mining Journal

scientists to represent data from several

(cited in an article by

variables on all possible minerals in a

Wipro, an IT, consulting and

single graph, according to the article.

business process company) reported

real-time (or near-real-time) analytics,”

“These visualisations can reveal patterns

that big data analytics would spur

says Chakraborti. He says the decisions

of occurrence and distribution that

the next wave of efficiency gains in

could then be applied to a wide spec-

might otherwise be hidden within a

ore extraction, analysis, transportation

trum of mining activities, including explo-

spreadsheet,” it states.

and processing by enabling faster and

ration, production and operations.

Big data for smarter operations

better-informed decisions.

Sandipan Chakraborti, senior architect

to taking the right mining decisions is, therefore, the availability of accurate data from multiple systems combined with

“They can also be used to monitor and report metrics and KPIs. Addition-

“It’s imperative that mining move

in Wipro’s energy, natural resources

ally, they serve to identify root causes

very quickly to embrace some of the

and utilities business, explains that data

for operational bottlenecks such as

innovative technologies that are giving

sources in the mining industry may

unscheduled truck maintenance de-

other industries a significant edge,” said

be classified as either direct or indi-

lays, long queuing times of trucks and

O’Neill at the tech forum in Las Vegas.

rect (ancillary) measurements. Direct

LHDs, delays in lab samples undergoing

He said big data could provide fresh

measurement sources are taken by

quality control and batch processing,”

business insight that could have spin-offs

instruments such as conventional geo-

Chakraborti adds. Another example is

in equipment maintenance, product

detic surveys and GPS. Indirect sources

in mine safety. Western Australia-based

refer to systems that collect data as a

company Synaptor used big data to

by-product of processes or operations

show how a mining project might help

such as fleet management systems,

to reduce accidents.

“3D printing and big data are some of the technologies that are low-hanging fruit, just within our grasp.”

Scada, DCS data, blast-hole drills and geomodeling data.

“To improve ore recovery, an ore-

The company used incident logs and other reports generated on large mining sites to analyse the stats. The system can

body modelling technique is used. The

then issue early warnings about risky

model provides geological patterns

behaviour or accidents.

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The use of remote isolation systems in mining It would be an understatement to say that mining is dangerous. Yet, while productivity is all-important in mining, as in any other business, so is safety.

So how can you have your cake and eat it? By Tony Stone

H

ealth and safety has come a

running machinery, the Occupational

long way in the last 20 years.

Safety and Health Administration and

Benefitting from reputable

other safety professionals recommend

research conducted by,

that workers and their employers:

inter alia, Janice Windau of the USA’s Bureau of Labour Statistics, we can act upon data and respond to findings.

• safeguard against contact with moving machine parts

An MSHA-approved underground ore conveyor belt system (Photo: R-Tek International)

•a void wearing jewellery and tattered or loose clothing around

• shut off power, perform lockout-tagout,

She concluded in a research paper,

and release residual energy before

‘Worker Fatalities from being Caught

unjamming, servicing, lubricating, or

in Machinery’, that to prevent further

adjusting machinery (exceptions may

injury and death from being caught in

apply for certain machinery)

machinery, and wear hair short or tucked inside clothing • avoid stepping over or reaching across running equipment • replace guards after servicing equipment.

By 2004, injuries and death caused

TABLE 1 Activity performed by workers fatally caught in machinery

26

by materials handling equipment in the USA had reached 17%.

CAUSE OF INJURY/DEATH (1997)

NUMBER

%

Operating machines

85

45

applications, took their regular toll

General (unspecified) repair or maintenance

37

20

with drive units, pulleys and belts

Unjamming materials

19

10

Cleaning machines

14

7

Adjusting machines

8

4

extreme conveyor belt applications

Reaching or stepping over machines

7

4

include an incline slope conveyor

Inspecting or checking machines

5

3

built at the Prosper Haniel mine in

Other

14

7

Total

189

100

INS I DE MI N I N G O C T / N OV | 2 0 1 7

Conveyor belts, particularly in mining

experiencing the most failures – and along with these failures, there are injuries and deaths. For example,

Germany, where coal extracted at depths between 700 m and 1 300 m is brought to the surface via a conveyor

MATERIALS HANDLING

Addressing incidents

Australia’s Innovation of the Year Award

A sharp proactive eye will spot incidents

in 2012. This RIS significantly reduces

developing before they occur, but how

the electrical isolation and reactivation

can they be dealt with? With necessity

time of bulk handling mining equipment

belt that has a vertical elevation of

being the mother of all invention,

such as conveyors, crushers, loaders,

approximately 780 m. In addition, the

inventors Michael Lane, Jack Mross, Julian

stackers and reclaimers.

belt simultaneously conveys millions of

Hughes and Phil Rohrlach, in response

tonnes of tailings on the return run back

to Windau’s second recommendation,

Defining RIS

to the bottom of the mine. Of necessity,

developed and patented the first Remote

In 2016, at the IEEE Industry Applications

this conveyor belt system needs to be

Isolation System (RIS). ICM Technologies,

Society Annual Meeting in the USA, Mike

constantly monitored so problems can

for whom the inventors worked, called

Lane defined the RIS as a mechanism

be resolved manually.

it Remsafe and promptly won Western

to remove personnel from potentially

A Remsafe fixed station mounted above a conveyor belt system

And in another instance, the world’s largest bucket wheel excavator, which is used to remove overburden and recover coal, stands 220 m long, 96 m high and weighs 13 500 t. This enormous machine moves 240 000 m³ per day at a rate of up to 40 000 tph. These production requirements exert the highest demands not only in the volume conveyed but in moving rocks measured in square metres in size. The conveyor belt used has a width of 3.2 m and an overall gauge of 45 mm. While these belts are ideally designed to withstand the forces exerted upon them, large rocks can and do fall off on occasion.

What can go wrong during isolation or deisolation? An arc flash can occur and inflict serious injury, which may even result in death (Photo: Miller Electric)

IN SID E M IN IN G OCT/NOV | 2017

27

MATERIALS HANDLING

dangerous tasks. It removes the element

possibility of being exposed to injury in

of human error, provides a safe, verified

an arc flash event is removed. Isola-

isolation and increases production out-

tion time is quick, from the request to

put through the time saved converted

isolate to lock out and tagging. As a

to production time. It does this by oper-

product, RISs should be fully compliant

ating electrical and mechanical isola-

with all appropriate local standards

tors simultaneously in just seconds. Multi-

in the functional safety of electrical/

ple isolators can be controlled per single

engineering and programmable elec-

system, all locked out in the isolated

tronic safety devices for SIL (safety

state at a single on-site lockout point.

integrity level) standards.

The system is safety rated and fully compliant to the relevant regulatory stand-

Give and take

ards, industry safety organisations and

Trade unions demand that mines do

company isolation requirements. It pro-

more to secure the safety of workers.

vides a faster and safer means to isolate

In so doing, and using technology to

compared to conventional methods.

do so, more and more manual tasks

The isolation and de-isolation process

are being automated – requiring less

being automated obviates the potential

human intervention. So, while the

for human error or human injury.

mines can have their cake and eat it,

The process is initiated in the field

trade unions and members are losing

by the person on the job. It does not

out in one way but gaining in another.

require skilled electricians or fitters,or

If the value of life and limb is immeas-

people travelling to switch rooms to

urable, remote isolation systems are

carry out the isolation, which means the

an absolute necessity.

Key features of the FIS • Entirely

wireless and as portable as any small suitcase • Compliant

with existing site lockout-tagout isolation procedures familiar to regulators and users of heavy machinery •O perates several electrical and/or mechanical isolators simultaneously, regardless of their location •P rovides a single lockout point for all of the equipment operated on a single system •C onfirms a zero-energy state prior to enabling the operator to turn the switch and lockout •B oasts long-range, reliable communication •E xtended-life battery that is charged from a wide range of AC and DC voltages •T he mobile FIS has a wireless range of up to 15 km

IN SID E M IN IN G OCT/NOV | 2017

29

PIPES, PUMPS & VALVES

Repairing pipe

infrastructure

Death and injury are not the only devastating consequences of seismic events in deep underground mines. Damage to infrastructure, especially pipe infrastructure, can also be a costly problem. By Tony Stone

T

he recent seismic event

pipe. The rock burst happened just as

at Harmony Gold’s

he had walked away. Sudden earth

Kusasalethu Mine near

movements or seismic tremors present

Carletonville, which left five

A complex network of pipes and cables in a mine tunnel (Photo: Tony Stone)

an unexpected and, unfortunately, often

amplification around underground

dead, measured 1.2 on the Richter

unplanned-for problem. While seismic

excavations and this effect needs to

scale. A tremor of this scale on the

movements and earth tremors aren’t

be considered in dynamic rock support

surface is described as a micro

seen as particularly common in South

design. This, then, is an ongoing mine

earthquake, often not felt and rarely

Africa, they still occur more frequently

safety problem that needs to be resolved

recorded by seismographs. But deep

than realised.

given the incidence of seismic events

underground, in a mine, a tremor of this

Xin Wang and Ming Cai of Canada’s

in South Africa’s mining belt – not just

magnitude can be devastating – as

Laurentian University, in their paper

to prevent the loss of life but also to

was the case in this instance. One of

‘Influence of wavelength-to-excavation

minimise infrastructure repair costs.

the rock drillers who escaped death

span ratio on ground motion around

in the Kusasalethu Mine disaster did so

deep underground excavations’, state

Water in, water out

because water was not coming through

that complex dynamic wave interaction

Transporting clean water down into a

to the drill and he went to check what

due to multiple frequency components

mine as well as collecting and transport-

he suspected was a broken water

in the seismic waves can cause wave

ing groundwater and water run-off up

Harmony Gold’s Kusasalethu Mine near Carletonville (Photo: Itumeleng English/ANA)

PIPES, PUMPS & VALVES and out of a mine requires a complex network of pipes, pumps and valves Peter Fraser of Hydro Power Equipment, speaking at the 4th International Platinum Conference, stated that, of the various underground energy sources available, localised hydropower with on-level, clean water recirculation is the most flexible, safe and productive. It can be used to power auxiliary

An example of the infrastructure damage caused be a seismic-induced rock burst (not the Kusasalethu Mine)

operations (such as watering down, sweeping, pod setting, pumping, timber sawing, etc.) and other drilling operations (e.g. roof-bolt drilling and development drilling).

Hydro drills use roughly 12 ℓ a minute.

Butt-welding, fusion-welding and flanges

metal clamps (also patented) were

have their strengths and weaknesses

tested by Renier Snyman of DPI Plastics

but, in seismic or geologically unstable

at 53 bar, as per SANS 130-1 and SANS

areas, there is only one real, lasting solu-

966-1, with no leakage or significant

tion – given the SABS and independent

movement, and declared fit for pur-

Drilling a 2.5 m hole can take at least

laboratory tests conducted. The patent-

pose as restraining couplings for PVC-U

2.5 minutes through granite rock, using

ed inventions of Ian Cartledge, of Perma

pipes in a 16 bar application. Sasol has

a total of 30 ℓ per hole. Depending on

Marine Couplings, provide extraordinary

also approved the Perma couplings in

the drill pattern for blasting or depth and

durability and unbreakable toughness in

water applications. These couplings are

setting for rock anchors, this could add

HDPE and PVC pipe systems – and make

available in up to 630 mm diameters

up to a substantial amount of water in a

installation quick, easy and cost-effective.

with development taking place using

tunnel that stretches kilometres in length.

SABS testing (Report No: 3571/1029585/

This then establishes water, transported

R150) of a 63 mm polyethylene pipe

larger diameters.

through pipes, as a critical resource/

assembly fitted with a Perma coupling

In conclusion

problem, which, if damaged by a rock

at 47 bar pressure and (Report No:

Many of South Africa’s mines are locat-

burst, will affect the productivity of a

5421/1166408/R255) a 110 mm pipe

ed in seismic and dolomitic areas with

mine. Depending on where the rock

assembly fitted with a Perma coupling

substantial pockets of underground

burst occurs, the problem presented by

at 32 bar resulted, in both instances, in

water. When installing pipe infrastruc-

fallen rocks may also be compounded

the pipe bursting with no visible failure

ture, one needs to take into account

by flooding.

or leak detected at the couplings. For

cost, reliability, robustness and flexibility.

other third-party couplings, the Perma

HDPE and PVC meet all these criteria.

110 mm and 160 mm external restrained

However, the secret is in the jointing.

Choice of pipe systems It can be said that rigid pipe systems are unsuitable for use in mines located in seismic or geologically unstable areas.

Jan Venter, CEO of the South African

An example of a groundwater-flooded mine tunnel (Photo: Tony Stone)

Plastic Pipe Manufacturers Association, in speaking about the use of plastic pipes in mining, states that pipes should have longevity and be break-resistant, as well as be a safeguard for the environment.

HDPE and PVC pipes, with their 70- to 100-year lifespans, are perfect fits for mine pipe systems that are correctly designed (for purpose), leak-free and durable for long-term use, as well as for use in rehabilitating old pipelines.

Putting it all together While HDPE and PVC are excellent choices for pipe systems, joining the pipe lengths together is absolutely crucial.

IN SID E M IN IN G OCT/NOV | 2017

31

COMMINUTION

Driving efficient energy use

Historically, motor control was a process as simple as turning a motor on or off through the use of a contactor control.

Although this method is still applied to reduce control complexity and initial capital outlay, modern drive technology has seen a major uptake in the mining sector over the last decade.

T

32

SEW-Eurodrive’s Movidrive modular application inverter, the first part of a product innovation that is an element of the new Movi-C modular automation system

SEW-Eurodrive – adapting solutions to client needs SEW-Eurodrive says it has focused

Since Black Friday, the industry became

increasingly on optimising energy

significantly smarter in terms of how it

requirements. Driven by dwindling re-

uses energy. Several innovations saw

sources, spiralling energy costs, stringent

the light as operators scrutinised mining

international regulations, and the trend

processes for more efficient solutions.

towards cutting carbon emissions, the

One field that saw a major shift in the

German drive manufacturer has put

last 10 years is that of energy-efficient

all its efforts in energy saving. To ensure

drive technology.

savings, numerous system components

Nearly 70% of all industrial electrical

have to be analysed to optimise the

energy use goes towards powering

full energy-saving potential of drive

electric motors, according to ABB.

technology applications.

These motors are the workhorses of the

Norman Maleka, national sales

he mining industry still has mo-

system, whether they be pumps mov-

manager, SEW-Eurodrive, says energy-

ments of panic when recalling

ing fluids, conveyors, fans moving air

efficient solutions that save the desired

Friday, 25 January 2008. For any

to compressors, or any other rotational

energy in one application could lead

mine manager, the term ‘Black

force. Drives – be they variable-speed

to a higher overall energy consumption

Friday’ would never have the connota-

drives or frequency drives – are de-

in another. It is, therefore, important to

tion of an internet super sale. Instead, it’s

signed to run motors based on the

realise that a one-size-fits-all approach

a reminder of South Africa’s power crisis

current process demand, instead of

is not ideal, he says. SEW-Eurodrive

forcing the three largest gold mines to

running them at full speed. A good

adopts a customer-focused, total-

shut down their operations while Eskom

example of using modern AC or DC

solutions approach for optimal savings.

dealt with blackouts across the country.

drives is the mining locomotive.

“A comprehensive range of resources

INS I DE MI N I N G O C T / N OV | 2 0 1 7

COMMINUTION is available to plant manufacturers

the range of drives. Within the family of

environmental impact, many of these

and operators to help identify energy-

drives, the Sinamics frequency convert-

solutions help extend the service life and

saving opportunities in the field of

ers were introduced to intelligently save

reliability of existing assets, which reduces

electric drive technology. This includes

energy. They take advantage of

an energy consulting service, based on

a system’s energy savings

a modular and customisable concept

potential and optimise

in terms of optimisation and technical

energy consumption.

implementation,” says Maleka. For

“Depending on the

example, SEW-Eurodrive offers an

application, you

energy-saving calculator as a free

can efficiently

software tool, which allows customers

regulate the en-

to compare the energy consumption

ergy consump-

of standard motors with that of energy-

tion for individ-

efficient motors.

ual demands by

The payback period of the investment required can then also be calculated,

aligning the motor

They also provide additional operational benefits such as improved productivity and safety, the

Nearly 70% of all industrial electrical energy use goes towards powering electric motors

speed. Energy sav-

with the results downloadable in PDF

ings of up to 70% are

format. In addition, the SEW Workbench

possible with fan, pump

project planning tool reveals the overall

and compressor drives,” says

energy consumption for a specific ap-

the diversified engineering company.

plication and its configured drive train in the form of an energy analysis report.

Some of the manufacturer’s latest product developments include the Movigear mechatronic drive system, which combines an energy-efficient gear unit, motor, and frequency

the need for capital investments.

company states.

According to ABB, the most dramatic energy savings in a system often stems from variable-speed drives, significantly raising the efficiency of electric motors.

“Electric motors are everywhere, and the machines they run account for more than a

The frequency converter portfolio

quarter of the world’s electricity

provides a comprehensive offering of

consumption. Installing variable-

energy-efficient drives – both in the low-

speed drives can reduce their power

and medium-voltage range.

consumption dramatically, typically by

Variable-speed drives extend service life

around 30%, leading to significant cost savings and reductions in greenhouse gas emissions,” states the company.

In Sweden, for example, a power

inverter. It has received

ABB, which also offers a wide range

the TÜV SÜD Energy-

of energy-efficient products, including

plant installed variable-speed drives to

advanced process control systems,

control the performance of the many

automation products and electrical

electric motors in the plant following an

equipment, has completed many

energy audit carried out by ABB. ABB

projects in the mining sector.

installed eight medium-voltage drives,

Efficient Plant Technology certificate. Other energysaving innovations include the Movidrive MDR regenerative power supply unit and Moviaxis multi-axis servo

In several examples, its solutions have

some of which replaced the existing

inverters. The effiDRIVE energy-saving

improved the energy efficiency of

resistor-based motor control systems.

solution allows customers to realise

underground and open-pit operations,

The improvements eliminated significant

energy savings by optimising energy

including ventilation, materials transport,

heat losses caused by the resistors and

consumption to reduce costs. The

minerals processing and energy-intensive

enabled the plant to produce an addi-

solution allows the customer to select

auxiliary systems such as water pumping.

tional 35 GWh of electricity per year, an

mature, energy-optimised components

In addition to reducing energy costs and

increase of about 5%.

from a system of modular components as the best fit for a specific application.

Energy frequency converters to regulate energy

The introduction of Movi-C represents a new generation of technology for the Bruchsalbased drive and automation specialist

Global electronics and automation specialist Siemens offers the Sinamics family of drives. The drives address the potential to reduce costs – from single-motor drives and drive converters with low power ratings, to vector drives and drives in the highest power range.

It therefore covers the complete range of power ratings with a unique, unified philosophy and operator navigation, which means simple entry into the system. Once know-how has been established, it can be directly transferred to other applications, e.g. using the tools for engineering, configuring and commissioning, which are applicable across

IN SID E M IN IN G OCT/NOV | 2017

33

MINE CLOSURE

Next-generation mine closure Mining companies need to collaborate closely as they start making financial provision to adhere to the NEMA GNR1147 legislation for mine closure. It is time for South Africa to start developing effective closure case studies. By Nicola Theunissen

T

he derelict mine dilemma plagues

their closure liability. The panel discussion,

Garyn Rapson, partner at Webber Wentzel

government entities, mining com-

hosted by Webber Wentzel at its head

and one of the panellists, addressed the

panies, consultants and legal firms

office in Sandton, explored the available

pieces of legislation that currently govern

alike. In the early 2000s, legislation

options for mining companies to turn

mine closure, touching on the drawn-out

shifted towards more stringent compli-

liability into reward. Panellists argued

debates between the mining industry and

ance related to environmental rehabil-

that trust in the industry can be improved

regulating spheres such as the Depart-

itation with the advent of the Mineral

through the responsible implementation

ment of Mineral Resources and the

and Petroleum Resources Development

of GNR1147. They argued that the inter-

Department of Environmental Affairs.

Act (MPRDA)(No. 28 of 2002).

However, the industry now faces Mine Closure 2.0 – a whole new wave of environmental and financial requirements to make provision for successful mining rehabilitation.

At an industry work-

“A radical mind shift is required... a mining company has to start a project with the end in mind.”

shop hosted on 25 July 2017 by Aurecon, the MSA

34

play between the complex web of interrelated legislation should be viewed as an opportunity rather than a burden.

More than 6 000 abandoned mines populate

The paperwork According to the most recent legislation, mines need to submit the following three documents: • A risk assessment report: determining the

the South African land-

potential financial liability associated

scape. Robert Appel-

with the management of latent

baum, partner at Webber Wentzel, says mine closures have been more costly and

intricate than mining companies

environmental liabilities post closure, and considering long-term water treatment risks.

• An annual rehabilitation plan: reflecting

Group and Webber Wentzel, in Sand-

realise. As such, the industry still does not

activities undertaken for concurrent re-

ton, lively debate took place around the

have a single case study or closure blue-

habilitation and remediation of the site/

implications of new mine closure legisla-

print to look up to when it comes to suc-

operations, year-on-year.

• A final rehabilitation plan: identify-

tion. The NEMA financial provisioning reg-

cessful mine closure in South Africa. The

ulations (GNR1147) have fundamentally

new NEMA requirements are pulling min-

ing and assessing final post-mining

changed the way mining companies

ing companies up by the proverbial boot-

land use for the operation, in addi-

need to plan for closure and will increase

straps in an attempt to find success stories.

tion to infrastructure and activities

INS I DE MI N I N G O C T / N OV | 2 0 1 7

MINE CLOSURE

LEFT In South Africa, the eMalahleni Water Reclamation Plant has been hailed as one of the country’s few successful long-term projects to address mining legacy issues. Aveng Water is currently expanding the plant for Anglo American Thermal Coal, from a capacity of 30 Mℓ a day to 50 Mℓ a day

companies around the funding vehicles for sustainable closure projects, if it is economically viable. Economies of scale for these projects are critical, and thus mines would have to collaborate and share infrastructure investments among each other to make such projects work. The importance of auditing was also addressed

to be decommissioned/remediated

during the workshop. Companies such as

upon closure.

KMPG, for example, have set out detailed

An important point raised by several

compliance guidelines for mining compa-

stakeholders is that mine closure should be

nies to ensure that they adhere to the new

considered a process, rather than a single

financial provisions necessary for GNR1147.

activity. “The financial provisions required

Stephan Herb of the MSA Group said the

to facilitate a successful mine closure and

new regulations are essentially about tak-

the accuracy of that forecasted amount

ing the long-term liabilities that are com-

need to find a home in a strictly regulated

monly associated with a mining project

and audited space if South Africa has any

and turning them into rewards that add

hope of changing its track record. It re-

value and save costs.

quires an integrated closure planning pro-

“A radical mind shift is required to one

cess to leave behind a sustainable eco-

where a mining company has to start a

system that addresses the inherent liability

project with the end already in mind,” he

aspect of mine closure,” said Rapson.

said. Tying in with Scholtz’s point, Herb said

Integration is key According to Aurecon’s Pieter Scholtz, the

mines need to apply systemic thinking within the new regulatory landscape.

Ben Burnand of the MSA Group con-

most important factor to consider in suc-

cluded that the new regulations are a

cessful mine closure within the new legis-

positive thing for the industry. He said the

lative framework is to follow a holistic, inte-

South African economy cannot afford

grated approach. He said environmental

to have funds lying around in trust funds

rehabilitation is only a small part of the

and, therefore, mines need to spend the

success of mine closure; the depth of the

funds they set aside for closure while still in

work lies in the complex socio-economic

operation by applying techniques such as

structures that surround the mines.

concurrent land rehabilitation.

According to Scholtz, mines need to

“The new legislation presents a great op-

fundamentally integrate their different

portunity to tell positive stories and would

departments (including labour, HR, en-

prompt the industry towards greater col-

vironment and engineering) to work to-

laboration,” Burnand concluded.

Three successful closure studies from abroad Panellists shared several best practice examples of international mine closures: •A phenomenal case study is the Eden Project in Cornwall, England. This “from pit-toparadise” story commenced in 1998 inside a reclaimed Kaolinite clay quarry. The surreal facility comprises large rainforest biodomes, an undercover ice rink and a wedding and conference venue.

•A nother example is the Kidston Dam, which was built to provide water to the Kidston Goldmine in Australia in the 1980s. Downstream properties receive water via a pipeline, which was built to supply the mine and associated townships.

Currently, a 250 MW pumped storage hydro project is planned at the dam.

•O perating for 100 years, the Sullivan mine in Kimberley, British Columbia, Canada, was once a major producer of zinc, lead and silver. Today, it is also a successful closure case study. After the mine closed, the owners replanted nearly 1 100 ha of former mining area. The water collection and treatment system was enhanced to manage and treat water from the site.

wards connectedness with and between municipalities’ integrated development plans (IDPs), governments and unions to bring about true sustainability. “And mines need to start doing it now so that it is not this ‘scary thing’ lurking on the balance sheet,” he said.

He further added that it is critical for the plans to be realistic, and that stakeholder engagement is the magic ingredient to ensure feasible closure plans.

Some of the questions that arose during the discussions were around equity investing in projects that could reduce closure liability, such as capital investment in water treatment and renewable energy.

According to Scholtz, banks would have provided a firm “no” as an answer two years ago, but are now increasingly open.

A representative from Nedbank said banks are certainly beginning to look at funding models and would be keen to engage in conversations with mining

IN SID E M IN IN G OCT/NOV | 2017

35

INVESTING IN

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MINING INDABA 2018

Investing in African Mining Indaba

As the expectations for responsible mining practices continue to grow, key stakeholders will gather at the Cape Town International Convention Centre and address the challenges that are preventing the successful implementation of a long-term vision in the African mining industry, as well as the necessary solutions.

T

he Investing in African Mining Ind-

Mining Indaba 2017

aba will kick off with the Ministerial

The overall feeling at the last Indaba

Symposium, which is a delegate

was a bit more positive compared to

favourite and the only event on

Unpacking the Indaba More information will be made available on Inside Mining’s dedicated digital platform www.miningne.ws regarding the Investing in African Mining Indaba 2018.

sentiments at the 2016 Indaba, with in-

To date, the MC3 has been at the centre

the African continent that engages the

dustry more confident about the future

of controversy between the South African

most prominent mining stakeholders in-

of mining.

Department of Mineral Resources and

cluding mining CEOs, African mining ministers and industry organisations.

This year’s Indaba focused on the intro-

the Chamber of Mines South Africa, after

duction of new technologies in the min-

Minister Mosebenzi Zwane announced at

ing industry, and the Chamber of Mines

the 2017 Indaba that the MC3 would be

4 February 2018, and sets the scene

noted that new technologies should

published at end of March. It was eventu-

for the rest of the Indaba conference.

not lead to job losses but rather offer

ally published on 15 June.

The symposium aims to create an ex-

good opportunities for mines to upskill

clusive platform for an open dialogue

their workforce.

The symposium takes place on Sunday

among the above parties, which ulti-

Since then, the industry lobby group has expressed its dissatisfaction regarding the lack of consultation from the department

mately results in stronger public-private

The ever-looming charter

cooperation and the highest level of

At the 2018 event, the controversial Mining

about in the industry, including R50 billion

developmental planning.

Charter lll (MC3) is also set to provide

that has been wiped off the market value

some important discussion points among

of shares in listed mining companies.

The rest of the Mining Indaba will see

and the damages the MC3 has brought

With the gazetting of the MC3, it will be

various event favourites taking place

stakeholders. Speakers may well highlight

from 5 to 8 February 2018, including panel

some industry concerns and provide some

interesting to see how it is incorporated in

discussions and stakeholder addresses.

recommendations for the mining industry.

the 2018 Mining Indaba proceedings.

IN SID E M IN IN G OCT/NOV | 2017

37

MARKET NEWS

MARKET NEWS

from around the continent Cummins growth in Zambia GLOBAL LEADER IN engine manufacturing Cummins is happy to announce its growing business offering in Zambia, as demand for backup power increases.

Meshach Kwegyir-Aggrey, recently appointed GM of Cummins Zambia, is responsible for its leadership, operations and strategic direction, and says the company is optimistic about the marketplace. It also has plans in place to accelerate business growth.

“Currently, operations are focused on the mining industry, with ambitions to expand the complementary businesses. Our clients have come to value the quality of Cummins products across our various business lines, including mining, filtration, power generation

and automotive. We have ambitious growth targets set for Zambia, as there are many opportunities in the market besides the established mining industry,” he says.

The reliability of Cummins automotive products will assist with logistical challenges in the country, where long distances between towns abound.

The company’s products comprise all genuine Cummins parts – part of the company’s ‘The Power of One’ approach – placing less stress on the product and thereby enhancing its life, ultimately lowering the high cost of inventory in a country where retro spare fits are often utilised.

Hydraulic breakers for FIFA World Cup RX breakers include a power boost feature that harnesses recoil energy

CIVIL ENGINEERING AND earthmoving specialist contractor Rock Fall Contracting WLL (RFC), which is based in Qatar, has augmented its fleet of Chicago Pneumatic rig-mounted hydraulic breakers with the addition of new RX8 and RX54 units.

The breakers are destined for use in demanding applications within the programme of infrastructure projects culminating in Qatar’s hosting of the IAAF World Athletics Championship in 2019 and the FIFA World Cup in 2022.

The hosting of these prestigious sporting competitions has spurred Qatar not only to build new eco-friendly stadiums but also undertake a total upgrade of its infrastructure. This includes major construction ventures such as an integrated road and rail network, as well as new drainage systems.

These initiatives, plus the new Hamad Port and the expansion of Hamad International Airport, are all part of scheduled upgrades to accommodate the anticipated vast

increase in tourists and passengers in and around Doha.

“Many of these critical projects have benefited from enhanced government spending to ensure they are delivered on time.

Our own ongoing investment in tough, reliable and easy-to-maintain construction equipment, such as RX breakers from Chicago Pneumatic, has helped us to cope with increased demand arising from these major civil engineering projects and boosted our reputation as an earthworks industry specialist,” explains Shaukat Ali, chief operations officer, RFC. Designed and robustly constructed for challenging dismantling, demolition and excavation duties, the key benefits of RX-series breakers include a power boost feature that harnesses recoil energy to achieve greater breaking performance without requiring additional hydraulic input.

They also feature energy-efficient gas/oil hybrid technology and advanced noise and vibration damping systems. In addition, for even greater durability in demanding applications, the latest models include a reinforced breaker box design with rock claws for better wear protection.

Meshach Kwegyir-Aggrey, GM, Cummins Zambia

Monitoring to raise mill efficiency MINES CAN NOW ensure higher efficiencies by tracking liner wear in real time thanks to the introduction of MultoScan by Multotec Rubber.

Unreliable and time-consuming monitoring of the condition of mill liners is a thing of the past and milling plants can now accurately measure a mill’s liner profile and predict the point at which the mill will start becoming inefficient.

The automatic measurement and display of the charge level confirms that the operation of the mill is correct.

According to Matthew Fitzsimons, technical manager, Multotec Rubber, wear rates of liners are not linear, as the increased slippage of the charge on worn liners tends to exponentially increase the wear rate.

Data generated by the MultoScan is analysed and interpreted by highly skilled technicians using Multotec’s Hawkeye proprietary programme, so there is no time lag, offering plants much quicker responsiveness.

“When combined with critical mill operating parameters, this data can help predict the point where the liner becomes inefficient and, hence, when the mill itself will become inefficient,” says Fitzsimons. “Customers can receive immediate feedback on the condition of the liners, so any urgent issues can also be timeously addressed.”

Repeatability of the MultoScan results means that there is hardly any room for human error in this system. It also saves mines significantly in terms of the time value of mill stoppages for taking manual wear readings.

IN SID E M IN IN G OCT/NOV | 2017

39

MARKET NEWS

from around the continent Mentis offers structural integrity THE USE OF STAINLESS steel in applications such as wastewater treatment plants is not only a safe and cost-effective option, but it does not compromise the aesthetics of the environment.

Recognised and accepted as the handrailing of choice in corrosive applications, Andrew Mentis’ stainless steel handrailing system has clean, modern lines that belie its resistance to hostile environments.

“In industries such as this, the combination of chemicals and water provide the perfect breeding ground for structural damage through corrosion. These plants, as well as petrochemical operations, require the highest possible protection against this,” says Lance Quinlan, marketing manager, Andrew Mentis.

The Mentis stainless steel stanchions are supplied in a range of standard angles with accessories to match facilitating versatility. The rails are manufactured from 304 stainless steel. The stanchion tube has a 45 mm outside diameter (OD) and a 1.6 mm wall thickness; this provides improved strength and structural integrity, ensuring that the stanchion is able to withstand the load factor from the horizontal hand and knee rails.

The handrail tubing and bends are 31.8 mm, with a 1.5 mm wall thickness. The components of the handrailing system and floor grating are engineered and manufactured to improve safety and reduce maintenance. They have also been manufactured to facilitate ease of installation without any special tools, concludes Quinlan.

Mentis stainless steel handrailing systems have clean modern lines

MSA launches self-retracting lanyard MSA AFRICA HAS launched its most compact and lightweight self-retracting lanyard designed specifically for environments where close anchorage is available.

“There is a legal obligation to have a comprehensive rescue plan in place when individuals are working at height,” says Nicolas Abry, business development manager: Fall Protection – MEAIR, MSA Middle East FZE. According to the safety company, the secret behind the Latchways 3 m personal fall limiter (PFL) is the use of multiple-spring, radial energy-absorbing technology.

“The new design eliminates the need for an external energy absorber outside of the housing, resulting in this being the

most compact PFL available on the market today,” explains Abry.

The company added that the precision engineering has resulted in a structurally reinforced pawl mechanism.

“Supplied with a choice of steel or aluminium top carabiner, with a range of connectors to select from, the retractable lanyard is suitable for a variety of applications. Not only does it require zero recalibration or adjustment, but a fully rotating attachment point allows for total flexibility, including 180 and 360 degrees,” said Abry.

The launch of the MSA Latchways PFL follows MSA Africa’s introduction of the Latchways personal rescue device (PRD)

– an integrated, unobtrusive rescue system contained in a small backpack attached to a full-body harness. It has been designed to be used in conjunction with a fall protection system or anchor point.

Both the MSA Latchways PFL The secret and PRD are examples of behind the the latest technology lanyard is the use of being introduced by multiple-spring, MSA Africa into the radial energylocal market to absorbing enhance worker technology – believed to be a safety in this world first regard.

36

ELB Equipment Terex

IFC

SBS Water Systems

18&19

KSB Pumps & Valves

2

INDEX TO ADVERTISERS African Mining Indaba Advent Oil

40

Dosetech 25

Loesche SA

ELB Equipment Sumitomo

Sandvik Mining

IBC

INS I DE MI N I N G O C T / N OV | 2 0 1 7

17 OFC, 4&5

Schneider Electric SA

38 OBC&22

SEW-Eurodrive 28 Tega Industries

15

ThyssenKrupp 6

Premset MV switchgear

Because a reliable network depends on safe, flexible, and maintenance-free switchgear Switchgear designed for enhanced peace of mind. Because business relies on the availability of electricity, buildings need their medium voltage distribution systems not only to be reliable, but also to be energy efficient, durable, and able to adapt to changing business needs. But the operators of these systems require more. Peace of mind is paramount, and can only be achieved with low-maintenance switchgear that helps ensure the safety of both people and assets. Switchgear that enables monitoring and lowers the total cost of ownership is critical.

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