Highly commended 2011 PICA Cover of the Year - B2B Publishing MEDIA
THE KNOWLEDGE YOU NEED
MineRP’s president, Pieter Nel, on the beneﬁts of enterprise mine technical solutions
PRESTIGIOUS PROJECTS IN AFRICA
ining FROM THE INDUSTRY EXPERTS
WEIR MINERALS A successful evolution
Accolades across the continent
SPECIAL FEATURE Electra Mining Africa 2012 ISSN 1999-8872 • R35.00 (incl. VAT) • Vol. 5 • No. 9 • September 2012
T H E K N O W L E D G E YO U N E E D
FROM THE INDUSTRY EXPERTS
ON THE COVER Well-established slurry pump solutions company Weir Minerals Africa has successfully evolved over the past few years to become a competitive player in the minerals processing sphere
P6 EDITOR’S COMMENT 3
What makes a prestigious mining project?
The top mining stories headlining this month
HOT SEAT 10 MineRP’s winning formula – enterprise mine technical solutions
HOT TOPIC 12 Commemorating mining’s people, places and longevity PRESITIGOUS PROJECTS IN AFRICA 16 Octea Mining’s new Sierra Leone sparkle 19 Montero Mining & Exploration: delivering an African mining first
22 Langer Heinrich: a world-class new generation uranium mine
24 Resource Generation’s Waterberg coal field aspirations 26 Stellar Diamonds tip toes forward with care and caution ELECTRA MINING SPECIAL 28 Atlas Copco 30 CSA Global 32 Regal Beloit South Africa 33 Haver Southern Africa 34 MBE Minerals 36 Marley Pipe Systems 38 Multotec 40 Tomra Sorting Solutions 42 Veyance Technologies 44 Pilot Crushtec 46 SEW Eurodrive 48 Osborn 50 Sandvik 54 Zest 56 Barloworld 57 Verder Pumps 58 Becker Mining South Africa 59 Melco MINERALS PROCESSING 60 An African minerals processing growth strategy 62 The processing key for low-grade uranium DRILLING AND EXPLORATION 64 Drilling safety needs standardisation 69 A new iron ore player on the Bushveld Complex 72 Endeavour’s fourth mine in the making CETERUM CENSEO 80 Investors still confused Inside Mining 09/2012
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Editor’s comment Publisher Elizabeth Shorten Associate publisher Ferdie Pieterse Editor Laura Cornish Head of design Frédérick Danton Senior designer Hayley Mendelow Senior sub-editor Claire Nozaic Sub-editor Patience Gumbo Marketing & online manager Martin Hiller Production manager Antois-Leigh Botma
WHAT MAKES A PRESTIGIOUS PROJECT?
It’s the little, or not so little, things that count
Production coordinator Jacqueline Modise Financial manager Andrew Lobban Administration Tonya Hebenton Distribution manager Nomsa Masina Distribution coordinator Asha Pursotham
Having decided to devote this issue to covering prestigious mining projects in Africa, I had to ask myself – what makes a project prestigious?
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Scale, volume and grade – the bigger the mine and the higher the grade, the more impressive the project… right? I am quite certain that these criteria are what most people would look at, it makes obvious sense. I, however, have delved a little deeper and made my evaluation for the projects covered in this issue based on a number of additional factors. The word ‘prestigious’ means many things. To me, it means excelling or pushing forward in the face of adversity; it means aspiring to achieve the unachievable and adapting your business strategy with flexibility and ease to meet the evolving needs of an evolving market. So as you will see, every story I chose to write and share with you is one of inspiration, sheer determination and, in most cases, includes the will to achieve an African first – often in the face of some kind of adversity. Octea Mining, perhaps still better known as Koidu Holdings, has developed the first large-scale, commercial diamond mine in Sierra Leone. Despite the logistical and infrastructure challenges associated with working in this remote country, the company recently announced its exclusive agreement with world-renowned jeweller Tiffany & Co. That’s an African first for sure! Montero Mining & Exploration is aspiring to be the first rare earth elements miner in Africa – from 2013 onwards. And despite its junior status, the company has every intention of building a full-scale rare earths refinery, which I hope will be in South Africa, adding another ‘first’ on this company’s achievement list. Paladin Energy’s Langer Heinrich uranium mine is another project achieving accolade upon accolade. It has just completed a Phase 3 expansion and is already looking to optimise its larger plant or embark on a fourth expansion, which could effectively double its current uranium production. No other uranium mine I know of keeps growing with such rapid speed. Resource Generation, an Australian-listed coal junior, is looking to be the first junior and second
company in the world to achieve coal production from the Waterberg. Despite the numerous challenges associated with this untapped coalfield, this is one junior who is taking difficulties in its stride and, if you ask me, will be successful regardless. Finally, Stellar Diamonds, which I am not ashamed to admit a soft spot for, is a company with vast amounts of promise. I have followed this company over the years and while it still has a long path to journey on still before reaching production, I have no doubt that its enduring commitment to ‘doing things properly’ will ensure its diamond success in Guinea and Sierra Leone (not to mention the longterm projections for the diamond market). So what makes a prestigious project? These mining companies are really showing their muscle and proving that working in Africa and achieving prestige is attainable!
Come check out our stand at Electra If our prestigious projects don’t keep you occupied, our Snowden pages (12 to 15) certainly will. In honour of Inside Mining’s stand at Electra, this four-page showcase will give you further insight to what you can expect at our stand. I look forward to networking and catching up with everyone over the Electra week. I have no doubt it will be a great success, so see you there. Laura Cornish
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latest updates and inside scoop from the mining industry. Check out what we are talking about on our website, Facebook page or follow me on Twitter and have your say. @mining_news www.facebook.com/pages/Mining-News
Inside Mining 09/2012
Mining news www.miningne.ws
Top mining stories headlining this month | AUSTRALIA | Rio Tinto advances sale of diamond mines as aluminium plan stalls compiled by Ameerah Griffin
Source: www.bloomberg.com Rio Tinto Group’s plan to sell its diamond assets is “well ad-
levels of supply and continuing strong demand.” Mining companies, including BHP Billiton, are shedding lessprofitable assets as declining prices and increasing costs trim earnings. Rio has reported a 34%
Rio Tinto's Argyle mine
| SOUTH AFRICA |
Lonmin’s epic disaster South African President Jacob Zuma announced a national week of mourning for the lives lost at Lonmin’s Marikana mine in Rustenberg. An inquiry has been launched as the country demands answers as to why police fired live ammunition into the crowd of striking miners, who were armed with traditional weapons. Thirty-four miners were killed and many were injured when police shot at striking miners. The strike action started with workers demanding a salary increase, which quickly turned into a turf war between two unions: the National Union of Mineworkers (NUM) and the Association of Mineworkers and Construction Union. The union leaders at Marikana lost control of the situation and were unable to calm angry miners. Violence erupted, leading to the death of two security guards, two police officers and miners not taking part in the protest. The death toll is 44. On Monday, 20 August, the 259 miners who were arrested appeared in court, where bail was denied. At the peak of the unrest, Zuma left Mozambique, where he was due to attend an African Union summit, to visit Marikana and launch an inquiry into the ‘massacre’. An inter-ministerial committee has been formed, led by Minister in the Presidency Collins Chabane. Lonmin gave workers until 20 August to return to work, but reconsidered this threat and backed off from firing workers who did not return to work. Former ANC Youth League leader, Julius Malema, who actively supports nationalisation of mining, addressed several thousand Marikana mineworkers, saying Zuma should step down, as well as police minister, Nathi Mthethwa.
Inside Mining 09/2012
vanced”, while the divestment of its aluminium operations has stalled after prices for the lightweight metal fell. The company is looking at multiple options for its diamonds division, CFO Guy Elliott, told reporters recently. “The diamond sector looks interesting and healthy, especially if you look into the medium and longer term, in view of the low
drop in underlying profits to US$5.2 billion (R43.35 billion) for its financial year. In October this year, Rio announced its intention to sell 13 aluminium assets, including smelters and alumina plants in Australia, the US and UK to improve its finances. Rio has also said it may consider an initial public offering for its Pacific aluminium unit.
| EUROPE | Anglo American completes acquisition of De Beers shareholding Source: www.miningne.ws Anglo American has completed the acquisition of its 40% shareholding in De Beers from CHL,
which represents the Oppenheimer family interests, thereby increasing Anglo American’s shareholding in De Beers to 85%.
Under the terms of the November 2011 agreement between Anglo American and CHL, Anglo American has paid a total cash consideration of US$5.2 billion (R43.35 billion), comprising the agreed purchase price of US$5.1 billion and a number of adjustments as provided for under the agreement. Anglo American was able to take over De Beers after the diamond-rich Botswana government, which owns a 15% stake in De Beers, agreed to forego its right to buy another 25%.
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WEIR MINERALS AFRICA
A successful evolution Well-established slurry pump solutions company Weir Minerals Africa has successfully evolved over the past few years to become a competitive player in the minerals processing sphere, writes Laura Cornish.
GROWING AND GROWING
012 is going to be a record year for Weir Minerals Africa, with forecast sales predicted to be higher than ever before,” says the company’s sales and marketing director, Gavin Dyer. “This can be attributed to a number of factors, but is largely owing to the increasing successes we are celebrating across our entire, broad product range. And although it has been a slow process, we believe we have gained market acceptance of our evolution from pump supplier to minerals processing solutions provider,” Dyer continues. And although the company will not be exhibiting at Electra this year, it will devote its time to hosting clients who are attending the four-day exhibition, in addition to devoting time taking its clients to site, across the globe, where its products are running successfully in various applications. In addition to slurry pumps, Weir Minerals Africa’s products include a range of dewatering and process water pumps, a range of mill lining systems, hydrocyclones, valves, vibrating screens, high-pressure grinding rolls, as well as rubber hoses and sheeting. Despite accommodating such a vast product range, the company is equally devoted to investing the time and money into the necessary research and development required to ensure it offers the market the latest stateof-the-art technology and upgrades. Investing in facilities is another important business component for the local company’s holding company, the Weir Group, and further guarantees that it can deliver on its promises. “We are doubling the size of our product ranges every one or two years, introducing
Weir Minerals Africa's offering includes slurry pumps, vibrating screens and wear resistant liners
Inside Mining 09/2012
new additions to our brand families. Our cyclone portfolio and screens portfolio have achieved sales far beyond our expectations,” Dyer mentions. Despite the company’s growing success, its future growth aspirations remain intact and business models have been executed to ensure personal and company targets are met and exceeded. It is no secret that Weir is acquisitive by nature. “There are definite gaps in the minerals processing stream that we have every intention of filling. We want to provide solutions and equipment across the entire process stream, while retaining our status as a premium supplier.”
Carrying the risk – and delivering on its promises One of the most innovative and client-attractive offerings is Weir Minerals Africa’s product trial period packages. “With new or unfamiliar products, we offer to operate the equipment on the m for a trial time frame mine frame,
which enables the client to determine whether the product is suitable or not. This is a very successful marketing exercise for us and is extremely effective in helping the industry become familiar with new products and their benefits. During this period, the operational costs of the equipment and the cost of the equipment itself is covered by Weir Miner-
A Linatex double deck banana screen prior to despatch to De Beers in June 2012
by a passionate management team. Weir Minerals Africa also places a lot of emphasis on individual employee growth and empowerment. Every product manager is encouraged and empowered to grow their portfolios
“We are doubling the size of our product ranges every one or two years, introducing new additions to our brand families” als,” Dyer explains. And the success is evident with 97% of the trial runs resulting in equipment orders. Trial periods on site also enable the company to identify areas for improvement, so changes can be made wherever necessary.
Empowering its employees There is a positive vibe amongst its employees, which to a large extent is generated
and aspire to take on more responsibility. “Through this, our staff are motivated, passionate and innovative, which all contributes to our company’s overall success,” Dyer points out. As a result, a number of the company’s employees have delivered first-time achievements (within the group) and are setting global benchmark standards. It is not just the company’s product offering that has changed, but the mindset of its employees and its devotion to offering clients solutions, not just equipment. The African subsidiary employs some 1 300 personnel, and is also working on improving its current Level 7 BEE rating. “Our focus here is aimed at investing at grass roots level, such as graduate development programmes.” The company has an extremely low staff turnover rate as well.
Changing perceptions Coupled
Warman AH 14/12 slurry pumps qu prior to quality assurance checking
Inside Mining 09/2012
ABOVE LEFT Weir Minerals Africa frequently hosts industry professionals in knowledge sharing sessions ABOVE RIGHT Isogate slurry valve placed in the Cavex cluster
business and brands is the necessity to change the face of the business, which Weir Minerals Africa has fulfilled. In essence, this means working equally as hard on weaknesses as maintaining strengths. “Our rate of deliveries, particularly on our pump brands, has been challenging, but we
to improve communication regarding each other’s needs and delivery capabilities. This aims to prevent disappointments for our clients.” The results are already evident. According to Dyer, the company has received praise from both mining clients and project engineers.
“2012 is going to be a record year for Weir Minerals Africa, with forecast sales predicted to be higher than ever before.” Gavin Dyer, sales and marketing director, Weir Minerals Africa have streamlined the manufacturing process and have reduced our overdue pumps to almost zero. Working with our own suppliers and instituting stringent deadline control has assisted us in improving our deadlines,” Dyer notes. “We are also partnering with our key account clients, working with them
At the end of 2010, Weir Minerals Africa initiated customer satisfaction surveys, which have provided the company with insight into the mining industry’s perception of its capabilities and areas that require improvement. “Even though we have come such a long way in changing the sector’s perception of who we
are and how we do business, this is only the start of our journey towards achieving greater success and is something we will continually strive to improve and uplift,” says Dyer.
An obligation to the industry “Our obligations extend further than supplying quality equipment and solutions to the sector. We also believe it is our responsibility to invest in upskilling future generations and driving new people into our industry.” Weir Minerals Africa sponsors university students and continues to supply technical equipment such as scientific calculators to science and maths students at school. The company has also assisted in starting new small-to-medium enterprises in the Middleburg region to uplift general skills in mining communities. Closer to home, the company more recently introduced a new concept internally, aimed at sharing knowledge across all company spectrums. Basic introductions across all of its product lines are a useful tool for all company employees to have, and even certain mining industry professionals have taken to joining in its knowledge sharing sessions. LEFT Two Cavex cyclone clusters in a coal mining application BELOW Warman AH 14/12 pumps prior to inspection at the quality verification station at Weir Minerals Africa’s Alrode facility
Inside Mining 09/2012
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ENTERPRISE MINE TECHNICAL SOLUTIONS
MineRP’s winning formula International mining technology and consulting company MineRP has achieved phenomenal growth over the past year. This has established the momentum that will see the company double in size by 2015, company president, Pieter Nel, tells Laura Cornish.
A JOURNEY PAVED WITH GOLD
lthough recognised in the mining industry today for his technological skills in the information and technology sector, Nel is a miner by heart. “My mining career started in 1991 when I joined international management consulting firm Byrne Fleming Consulting. I spent my time working underground shifts, looking at optimisation plans for major mining companies like Gold Fields,” Nel begins. He went on to join Kingsley McAdams Consultancy (KMC) in 1995, which was acquired
by MineRP – formerly known as Graphic Mining Solutions International (GMSI) – in 1998. “I very quickly became involved in the technological processes and systems that MineRP has become globally recognised for, particularly enterprise mine technical solutions development. This portion of the business generated 65% of the company’s revenue around that time,” Nel continues. “Like me, the majority of MineRP’s current employees have considerable mining backgrounds, which have combined successfully with the information technology business aspect. This is not typical in this line of business, and it’s something I believe has grown to emerge as a true competitive edge.” In 2006, Nel was appointed MD of MineRP and has continued to contribute significantly towards the growth the company has already achieved and is working towards.
MineRP: formed on solid foundations Perhaps less well-known are the roots upon which MineRP has grown. The company was established as a subsidiary to Anglo American gold division in 1997 and focused on mine technical systems and solutions development,
“MineRP is the only technology company capable of providing framework integration across every mining value chain component.” Pieter Nel, president, MineRP from geological modelling through mine planning and operational management. Jim Porter, Director: Centre for Mechanised Mining systems at the University of the Witwatersrand, was MD of the company at the time. In 1998, the company was acquired by international ICT company, Gijima Holdings. GMSI was rebranded in October 2011. “MineRP better reflects who we are and best positions us to achieve our global growth targets.” Today, MineRP has worked with every major mining house in South Africa, including AngloGold Ashanti, Anglo American Platinum, Spatial analysis of Block Model colour coded to grade
Inside Mining 09/2012
Anglo American Thermal Coal, Gold Fields, Impala Platinum, Harmony Gold, Lonmin, Kumba Iron Ore, De Beers Consolidated mines, BHP Billion Coal South Africa and Xstrata Coal South Africa. The company most recently implemented mineral resource management and enterpriselevel integrated planning solutions for one of the world’s largest iron producers, BHP Billiton Iron Ore, including its multi-mineral ore body, the Olympic Dam mine in Australia – one of the first such implementations outside of the East, Middle East and African region.
The last financial year (July 2011 – June 2012), and the path to 2015 “We have had a phenomenal year and financially performed better than any previous year,” he says. According to Nel, the company is also the largest research and development investor in its business sphere – specifically with regards to mine technical solutions. The company recently appointed numerous highly skilled technologists, who will deliver more controlled and structural solutions to the market. “We believe the sector is ready to advance its enterprise solutions, and bringing specialist technologists on board to inject into the industry will help us achieve our growth aspirations. We have furthermore identified the need to partner with the right international and local partners in order to secure the process we need to follow to double in size by 2015,” Nel outlines.
The MineRP advantage and competitive edge MineRP has taken huge steps in fostering closer relationships between providers of mining technical solutions around the globe that traditionally focus their solutions on various functions across the mining value chain. With formal, published invitations to other vendors to integrate their solutions with MineRP’s SpatialDB platform and multiple such integration arrangements already in place, the company is steadily moving towards a situation where system developers can focus on their area of speciality – be that geological data management, mine planning and scheduling, survey, optimisation or any such technical function – leaving the intricacies of data integration to MineRP. This allows mines to deploy expert mining technical systems of their choice throughout
Spatial analysis of Design & Actual OverUnderbreak
their global operations without the need to standardise on a single vendor. Not only does SpatialDB allow for data integration, but it also provides mines with the ability to globally collate and visualise massive sets of mining technical data using SpatialDash, a web-based data visualisation and analysis tool, on any mobile or desktop device capable of browsing the internet.
The three pillars of growth: • Geographical expansion – while MineRP has numerous well-established branches across the world, the intention is always to expand further. The company is in the process of establishing its first African branch outside of South Africa in Ghana and another in Adelaide, Australia. Current offices: • South Africa: Rustenburg and Centurion • Eurasia: Istanbul
• Latin America: Santiago • Canada: Sudbury, Calgary and Toronto • US: Denver • Australia: Brisbane and Perth • Expanding and further developing capabilities for the company’s second business component – consulting and advisory services • Further developing technology to support integration of information across the entire mining value chain. “MineRP is the only technology company capable of providing framework integration across every mining value chain component, regardless of the software and systems installed,” Nel notes. Many companies in the mining technical software space provide systems that integrate with each other, but MineRP has taken a giant leap forward with the development of SpatialDB – an open standards-based database, designed with specific connectors and extensions suitable to collect, interpret, unify and visualise data from a variety of sources – not only MineRP’s own systems.
Spatial analysis of Design vs Actual
Inside Mining 09/2012
A PHOTOGRAPHIC CELEBRATION
Commemorating mining’s places people, and longevity
Le Cong Binh, who won the best composition for his photograph titled ‘The road to the quarry’.
LEFT Tailings dams can be a major source of water pollution if not managed properly
Inside Mining 09/2012
The mining industry never fails to arouse emotion in those who come in contact with it, and this was certainly the case with the entries for Snowden’s 2012 photo competition, ‘Celebrating the Mining Industry’.
he technology solutions company, which is celebrating its 25th anniversary this year, has good reason to celebrate the industry through its annual photo competition - an opportunity to promote and educate about the industry in which it has been involved for a quarter of a century, and which touches so many aspects of our lives., The overall 2012 winner, who received US$10 000 (R80 925), was Javier Arcenillas from Spain for his photo, ‘The industrialisation of Lithium in Bolivia’. Arcenillas was exposed to mining from a young age in Bilbao, Spain, where he grew up near mining activity. Ray Collins has worked in underground
Ray Collins for his photograph titled ‘Through the arches’ in the ‘People in mining and their stories’ category
Inside Mining 09/2012
coal mining for almost 10 years. When asked about what inspired the photograph, his response was a reflection of the people in mining. “I work with some interesting looking people, people whose faces tell a story, the story of their life, and you can see experience and hard work etched into his face.” Jim Ward’s photo, he believes, is a good illustration of the industry’s focus on safety. “This picture, which shows people working in a daunting environment specifically to
Inside Mining 09/2012
create safe working conditions for others who will eventually work in the pit, speaks volumes about the industry’s commitment to safety.” Snowden CEO, Craig Morley, commented on the themes running through the submissions this year: “We had a lot of photographs on sustainability and revegetation, and the community elements of mining. These are reflective of a global industry that is a part of our lives, one where the future needs to
Nikki Sandino Victoriano –‘Mine worker’s children living near quarrying site are actively participating in tree planting in their community” in the ‘Environmental or sustainability successes in mining’
be managed as well as the present.” “Having been in the industry for 25 years, Snowden has seen the mining booms and busts, it is great to see the photos submitted reflecting a theme of an evolving industry that is also planning for a sustainable future.” The Snowden photography competition, now in its eighth year, is an annual event, which runs from 1 January until 30 June. The competition is open to amateur
photographers across the globe, with photographs submitted online through the Snowden website. The top photographs are exhibited at a variety of industry events around the world. This year the exhibition will be open for a two- week period in Perth at Central Park Office Tower in early October and will then move to the Riverside Centre in Brisbane from the end of October, before moving to Johannesburg in January 2013.
Jim Ward ‘High wire act with a difference’ in the ‘Technology and innovation in mining’ category
OVERALL WINNER Javier Arcenillas, ‘The industrialisation of Lithium in Bolivia’
Inside Mining 09/2012
Prestigious Projects in Africa
AWASH WITH DIAMONDS
A new sparkle for Sierra Leone
The Koidu diamond mine in Sierra Leone has created the foundation for a new diamond player – the Octéa Diamond Group – which plans to open more mines in the country in the near future.
he president of Sierra Leone, Dr Ernest Bai Koroma, delivered a message at Octéa’s glittering launch event at the mine in July, acknowledging the role played by Octéa in nurturing the diamond sector in the country. “Our country has been blessed by significant mineral wealth, but the way that we manage this wealth is vital to the future prosperity of the country and the upliftment of its people,” said Koroma. Octéa’s progress to date “mirrors
government’s commitment to true development partnership, in accordance with international best practice,” he said. “We have entered a new economic era in which the private sector is playing a pivotal role, and we thank Octéa for its contribution.” Octéa’s CEO, Jan Joubert, says that four wholly owned subsidiaries of the Octéa Diamond Group have been established: Octéa Mining, Octéa Diamonds, Octéa Services and the Octéa Foundation. The name Octéa was chosen to reflect the quality of the octahedral diamonds characteristic of the diamond deposits in Sierra Leone. The group’s flagship Koidu diamond mine, located in Kono District some 330 km east of the capital Freetown, recently expanded production capacity with a 180 tph processing plant. The added facility will boost the mine’s diamond output from 10 000 to 45 000 ABOVE Plant commissioning LEFT The Honourable Minister of Mines in Sierra Leone, Alhaji Minkailu Mansaray, addressing the guests at the launch of the Octea Diamond Company
Inside Mining 09/2012
carats per month during the third quarter of this year, effectively doubling diamond exports from Sierra Leone. The mine now employs 1 570 permanent staff, 89.8% of whom are Sierra Leoneans. “The spectacular quality of our diamonds, together with the positive impacts our operations are having on our local communities and the country, have attracted interest from leading retail jewellery chain Tiffany & Co, with whom we have entered into an exclusive off-take agreement,” says Joubert. The Octéa Diamond Group is fully owned by BSG Resources, the diversified natural resource arm of the Beny Steinmetz Group of Companies (BSG), which also includes a foundation in its corporate structure. Since 2003, BSG has invested more than US$300 million (R2.46 billion) on the development of its operations, related infrastructure and social development projects in Sierra Leone. Joubert adds: “These diamonds enable us to finance the development initiatives that are bringing so much good to the people of Kono and the country. Plans are being
Prestigious Projects in Africa LEFT The 180 tph plant commissioning BELOW LEFT Plant erection
At the launch event, Sierra Leone’s Minister of Mines and Mineral Resources, Alhaji Minkailu Mansaray, highlighted the importance of mining for the future growth of Sierra Leone’s economy. He said that the country’s recent record growth rates are due largely to the mining industry and the contributions of companies like Octéa. Paying tribute to the Koidu mine, he said: “What has been achieved here is indescribable and simply remarkable. It makes nothing of the inherent challenges that normally be-
“We have entered a new economic era in which the private sector is playing a pivotal role”
made to put the proceeds from increased diamond sales into extending the benefits of our development programmes to those in the wider Koidu and Kono communities. As we move forward with our development plans, we are committed to bringing more
substantial change to the lives of the people of Sierra Leone.” The Octéa Foundation will also leverage its philanthropic impact through linking with other organisations that share its vision for development.
BELOW LEFT First diamonds recovered BELOW RIGHT Seen undertaking a launch day tour of the final recovery unit at the Koidu Diamond Mine were Jim Fernandez of Tiffany & Co; shareholder, Dr Beny Steinmetz and Robert Leitao of Rothschild with Jan Joubert, CEO of Octéa Diamond Company
set the operations of mining companies in the country, be it resource mobilisation or attracting the very best to come and work in Sierra Leone. “If anything, it provides an apt demonstration of what can be achieved when you have a committed shareholder, a dedicated management team and a professional workforce. With this rare combination, an organisation can achieve wonders. And what Koidu Holdings [now Octéa Mining] has done with the Koidu kimberlite project [now Koidu diamond mine] is nothing short of that.” Octéa Mining, the holder of the mining assets of the group, also includes Tonguma, which is achieving promising exploration results. It is situated just 60 km south of Koidu. Another exploration licence to the east of Koidu has been awarded to newly formed subsidiary, Boroma. Joubert explains that Octéa is busy with the first phase of economic evaluation at Tonguma and will conclude a feasibility study in the first quarter of next year. Apart from Koidu and Tonguma, the company is also pursuing other opportunities, with the aim of producing at least two million carats by 2018. Operating in an environment where skills are in limited supply, the company has prioritised the training and development of human resources. “In addition to being good corporate citizens and ensuring our shareholders a good return, we want to be the company to work for in Sierra Leone, so we pay special
Inside Mining 09/2012
Prestigious Projects in Africa
attention to our relationship with staff and suppliers,” said Joubert. “This starts with good conditions of service, which create a secure and sustainable working environment. We then create opportunities for personal development, to stimulate individual growth through
ABOVE LEFT The Koidu diamond mine employs 1 570 people with 89.8% are local Sierra Leoneans (End July 2012) ABOVE The Kimbadu resettlement village at the Koidu diamond mine has clean pipe-borne water with tap stands
training and development programmes. The bond between the company and the individual goes beyond a written contract. Employees wear their uniform and ID with pride,
and have a sense of belonging and commitment that pulls individuals into teams, teams into a company, and a company into a family.”
Prestigious Projects in Africa
AN AFRICAN MINING MILESTONE
Delivering rare earth elements in 2013 Next year will be a milestone year for Africa’s mining industry as the continent’s first rare earths elements project is targeted to come on stream, Dr Tony Harwood, president and CEO of Montero Mining & Exploration, tells Laura Cornish.
he dynamics of the rare earths elements (REE) sector is changing as the world’s dominant producer and supplier – China – exports less and conserves more of its own production for its own use. The result is a significant surge of REE development companies seeking alternative deposits and independence from the singlesource REE country. TSX-V listed REE explorer and developer Montero Mining & Exploration (Montero) is not only aspiring to add its name to a fairly short list of REE producers, but intends to become the first REE mining production company in Africa.
Wigu Hill Phase 1 The company’s 70%-held Wigu Hill prospect in Tanzania has proven to contain a variety of
light rare earth oxides (LREOs) at unusually high grades, with values of up to 27.25% total REOs (TREO) from initial grab sampling and up to 16.68% TREO from drilling. Its REEs include cerium, lanthanum, praseodymium, neodymium as well as minor amounts of heavy REE oxides (HREOs). The prospect was first identified in the 1950s and has recently been defined as a large carbonatite complex (6.4 x 3.2 km), which has been intruded by REE-rich bastnaesite mineralisation in numerous dike swarms across the complex. It is 170 km from the Dar es Salaam seaport and 12 km from a railsiding on the Tazara railway. “Unlike typical REE monazite deposits, bastnaesite contains almost no radioactive thorium or uranium, which remains one of the greatest development and
disposal challenges for REE project developers,” explains Harwood. Since Montero’s establishment in 2007 and its initial public offering in February 2011 on the Toronto Venture Exchange (TSX-V) with the symbol MON, the company has announced an 43-101 compliant resource of 3.3 Mt with an average grade of 2.6% LREO, including a 510 000 t portion averaging 4.4% LREOs based on only 2 224 m of shallow drilling on the hill’s eastern ridge at the Twiga and Tembo zones. The detailed exploration undertaken to date has covered less than a third of the anomalous area of rare earth interest. Drilling and trenching has identified an extensive zone of carbonatite-hosted bastnaesite-rich mineralisation. The upside potential is still open ended and the exploration focus will be the
Exploring in Tanzania
Inside Mining 09/2012
Prestigious Projects in Africa
ABOVE Mike Evans, Project Manager showing near surface mineralised material at Wigu Hill
mineralised carbonatite zones identified here and their continuation to the north and west. And the ultimate success is already evident: Wigu Hill falls neatly in line with the company’s vision to emerge as a low-cost producer. As the project’s name suggests, the prospect is literally a hill, lending itself to economical opencast mining. It is also highly mineralised, is course in texture and is unweathered. “While this is more than sufficient for us to reach an initial production start-up in 2013, building up to about 5 000 tpa of mixed REEs, our intention is to drill and define a substantially larger resource by the end of this year.
The latest results include 2.24% TREO over 112.4 m (including 3.92% TREO over 14 m and 3.65% TREO over 16 m), 3.04% TREO over 42 m (including 3.8% TREO over 20 m) and 3.11% TREO over 44 m (including 4.31% TREO over 14 m). These latest positive trench results continue to confirm the extent of the mineralisation on the Lower Nyati Target. They substantiate the highgrade TREO values returned from the grab and panel sampling programme, and from the initial trenching and drilling results. The company has also commenced with an environmental impact assessment (EIA), environmental and social impact assessment
BELOW Wigu Hill’s bastnaesite-rich core drilling at Twiga
The detailed exploration undertaken to date has covered less than a third of the anomalous area of rare earth interest The target this year is 10 Mt at an average grade of 5% TREOs,” Harwood continues.
The drilling plan: • drilling to define inferred resource: 2 224 m (21 holes) – completed • Twiga infill drilling: 895 m (17 holes) – completed • drilling at Tumbili and Nyati targets: 2 555 m (11 holes) – completed • 5 000 m drilling programme for Nyati target – targeted to be completed in 2012.
(ESIA) and the grant of an extension to the prospecting license for the project area. The EIA and ESIA are crucial steps in obtaining the environmental permit, required for the mining licence application and any mining operation at Wigu Hill. Montero has engaged MTL Consulting, a Tanzanian company with skilled professionals in mining and environmental areas with local and international experience, to carry out the necessary studies. The scoping study and terms of reference examining the biophysical environment and socioeconomic environment of the project have been approved by the Tanzania’s National Environment Management Council, and the EIA and ESIA at Wigu Hill are under way.
Processing and refining Montero will not only mine the Wigu Hill prospect, but process the material in two separate phases. “2013 will not only see our production start-up, but also the completion of a process plant, which will deliver a bastnaesite concentrate.” In March this year, the company signed a non-binding memorandum of understanding
Inside Mining 09/2012
Prestigious Projects in Africa (MOU) with Star Earth Minerals, a rare earth chemical company based in Mumbai, India. Star is seeking to secure a consistent supply of LREOs from Wigu Hill (of between 1 000 and 3 000 tpa of mixed REEs and cerium) in order to supply its customers in the glass, ceramic and catalyst industries. The main objective of the MOU is to outline the basis of cooperation between Star and Montero with the objective of signing an off-take agreement for Star to purchase mixed rare earth and cerium carbonate from Montero. It also contemplates sharing technical information related to rare earth process technology for the development of a rare earth refinery to further beneficiate material from Wigu Hill. Through hydrometallurgical testwork with Mintek, Montero has already produced samples of saleable rare earths that were instrumental in concluding discussions with Star. “The signing of an MOU off-take agreement is the first step in de-risking Wigu Hill, while securing end-user distribution channels ultimately designed to generate REE sales revenue for Montero. Star is a producer of rare earth chemicals to the
BELOW The hill that will be mined
Asian market, with considerable expertise in rare earth refining, which also complements our fast-track to market strategy,” Harwood outlines. The ultimate mid-term aim, Harwood continues, is to build a fullscale REE refinery capable of delivering an initial 5 000 tpa and ultimately 20 000 tpa of individual rare earth elements. Refining will occur as a two-stage process; the first stage involves taking the bastnaesite concentrate, leaching and precipitating it to produce mixed REE material. The second phase, which still requires numerous testwork stages with Mintek, will look to separate the REEs into the individual elements (Ce, La, Pr, Nd and mixed heavy REOs). “Building a refinery of this scale is a massive financial and construction undertaking, and we have already embarked on a scoping study aimed at determining the best location, which includes South Africa. The source of funding and our strategic partners will largely determine its ultimate location,” Harwood notes.
Wigu Hill Phase 2 Reaching its 10 Mt target resource is just the beginning of Wigu Hill’s near-term prospect. Phase 2 is expected to grow this resource to 40 Mt. “With a project of this size and quality, we are very similar to the Mountain Pass REE project, owned by NYSE-listed Molycorp,” says Harwood. MolyCorp is in the process of developing a 19.6 Mt resource bastnaesite REE project in California, which is forecast to produce 40 000 tpa of separate element REEs at nameplate capacity, with a grade of around 9%. “With a 40 Mt resource, we could ramp up our annual production to 20 000 tpa, which we expect to achieve in 2015/16.”
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Prestigious Projects in Africa
A world-class new generation Namibia-based uranium mine Langer Heinrich is one of two new generation (conventional) uranium projects in the world, and has been successfully expanding ever since it first started producing, writes Laura Cornish.
ocated at the foot of the Langer Heinrich Mountain in the Namib Desert in western Namibia, the Langer Heinrich mine is in close proximity to the major port of Walvis Bay and Swakopmund. It is 100% owned by Paladin Energy, a uranium-focused company listed on the Australian, Canadian (Toronto) and Namibian stock exchanges. Considering it was the company’s first uranium-producing mine – and remains the largest producer within Paladin’s two operational mine portfolio – Langer Heinrich will retain its flagship status for the foreseeable future. “The mine is truly a success story, considering it has undergone three major expansions since its start-up production date in 2008,” says Paladin Energy’s executive general manager, Mark Chalmers. Having reached its initial production of
Inside Mining 09/2012
2.6 Mlb/year of uranium oxide (U3O8) in 2008, the mine completed a Stage 2 expansion to 3.7 Mlb/year in 2010 and, most recently, completed a Stage 3 expansion to 5.2 Mlb/year. “Stage 3 was initiated in the same year
(2010) that we achieved our Stage 2 nameplate capacity, and has been delivering at ABOVE AND BELOW: An aerial and long distance view of the Langer Heinrich processing plant
Prestigious Projects in Africa
uranium mine its designed nameplate capacity, at the 5.3 Mlb/year rate, for the last three months already,” Chalmers continues. Major engineering and construction company Aveng through its mining engineering house subsidiary E&PC, was responsible for the plant expansion EPCM contract. With a number of pits mined out since start-up, Langer Heinrich will look to dispose its tailings material in-pit within the next 12 months, which will help reduce the mine’s environmental footprint. “Although we have started with the feasibility study work aimed at commencing with a Stage 4 expansion, increasing production up to 10 Mlb/year, we have decided not to complete all aspects of the study at present,” Chalmers explains. The reason for this is twofold – the first being that although uranium prices remain fairly stable at present, Paladin would look to see it increase by at least US$20/lb (R164.74/lb) to ensure another expansion would be economically viable. The current average price for uranium has softened over recent months, settling around US$50/lb. “The short- to mid-term outlook for uranium is expected to increase to about US$70/lb, although we could ideally like to see it stabilise closer to the US$100/lb mark,” Chalmers mentions. “The second reason is that we are also investigating and exploring opportunities to
KAYELEKERA • The second new generation uranium mine Paladin (Africa) is a member of the Paladin Energy group of companies and is the corporate entity that holds the group’s interest in its second operating mine, Kayelekera. The Malawi government holds 15% shareholding in this company. The Kayelekera mine is located in northern Malawi, 52 km west of the provincial town of Karonga and 575 km north of the capital city, Lilongwe. Kayelekera was officially opened in April 2009 and has now reached design production rates of 3.3 Mlb/year of U3O8. The mine’s lifespan is eight years at the 3.3 Mlb/year rate with potential for a further 1.1 Mlb/year U3O8 for another four years. There is also scope to increase the mine life with ongoing exploration in the local area. the mine has 15 MW of secured commercial power (as well as on-site generators for emergencies).
Because Langer Heinrich is such a large deposit, it has the capacity to produce at large economies of scale optimise our recently commissioned Stage 3 plant equipment with regard to further uprating of process capabilities and thus output,” Chalmers adds. “While the larger plant is running and functioning well, we believe there is definite opportunity to optimise on the equipment and increase the plant’s output capacity.” The large-scale pit averages depths of 60 to 70 m and is expected to achieve a lifespan of at least 20 years It has been a relatively smooth transition between expansion phases, considering
Although water is a constraint the desert country, the mine is connected to the main water pipeline from Swakopmund. “We do need to ensure that we manage our water consumption carefully and conserve our usage wherever possible.”
The reasons behind the expansions Because Langer Heinrich is such a large deposit (with a 75 000 t U3O8 resource), it has the capacity to produce at large economies of scale. Its average grade – about 600 ppm (parts per million) – is relatively low in
comparison with global uranium mines, further necessitating its large mining volumes. The operation is viable and financially profitable at these grades, particularly with the cutting edge technologies that have been applied, Chalmers notes. Compared with Rio Tinto’s mature Rössing uranium mine nearby, Langer Heinrich grades are high. Expanding the mine in stages means the mine is able to generate cash to provide capital funding for expansion costs. THE REMAINING DEPOSITS AND PROSPECTS • • • • • •
Agadez: Niger Michelin: Canada Valhalla/Skal: Australia Bigrlyi:Australia Angela/Pamela: Australia Manyingee: Australia (potentially set to be Paladin’s third operational mine with resource drilling currently under way) • Oobagooma: Australia
Inside Mining 09/2012
Prestigious Projects in Africa
DELIVERING A NEW WORLD-CLASS COAL MINE
From the Waterberg Exxaro’s Grootegeluk mine may be the only coal mine successfully operating in the Waterberg coalfields, but not for much longer. A large-scale, newgeneration project is on track to start producing from the region from the beginning of 2015, writes Laura Cornish.
PAVING THE ROAD TO CONSTRUCTION START-UP
he lack of logistics infrastructure remains the primary factor influencing the speed (or lack thereof) at which coal mines develop within the Limpopo-based Waterberg coalfield. Yet ASXlisted Resource Generation (ResGen) has taken such challenges in its stride and overcome them. Not only has the coal developer invested the time and cash into developing
Inside Mining 09/2012
its massive new Boikarabelo coal mine in unfamiliar territory, but has also secured all regulatory requirements necessary to raise cash and build its mine – in just four years. Two months ago, the company’s BEE subsidiary Ledjadja Coal, an integrated part of the ResGen management team, signed a tenyear take-or-pay rail haulage contract with Transnet Freight Rail (TFR), allowing the
mine to haul up to 6 Mtpa of coal. “This was the last major hurdle we needed to overcome before proceeding to raise project finance and, ultimately, start with construction of the mine and necessary infrastructure,” explains ResGen MD, Paul Jury. “Our agreement with TFR is a significant step towards opening up the Waterberg region,” he adds. Since the TFR announcement, ResGen has been talking to numerous banking institutions, both local and abroad, which are under way with detailed project due diligence studies, but are already showing considerable interest in the project. Capital expenditure is calculated to be US$750 million (R6.25 billion). “We need a debt facility to cover about half of this that, once secured, will leave us to source the remaining amount from equity markets. I anticipate having enough cash in hand to start construction by the end of this calendar year, enabling us to move into production early in 2015.”
The Boikarabelo mining plan Reserve: 6.4 billion tonnes; probable reserve: 745 Mt Although production start-up is the primary goal, Boikarabelo already has a long-term plan in place – entailing a major expansion. Phase 1 entails an opencast operation and
Prestigious Projects in Africa THE TRANSNET AGREEMENT “We have had to make compromises in order to achieve a signed contract with TFR, in particular agreeing to a condition for the allocation of capacity. We are confident, however, that Ledjadja Coal will be provided with its required allocation because our studies show that sufficient rail capacity for our target production should be available once TFR has completed the minimal upgrade works that are required. We have indicated we are prepared to complete these works for TFR if there is a delay.” The main terms of the contract are as follows: • The initial term is for 10 years, with provision to extend for a further 10 years. • The contract allows for 4 Mt in the first year, 5 Mt in the second year and 6 Mtpa thereafter. Should Eskom elect to contract directly with TFR (which is Eskom’s intention) for the proposed domestic purchases currently under negotiation, the take-or-pay quantities in the contract will reduce to export tonnage only. • The contract specifies an indicative tariff for the current year. The actual tariff will be determined annually by negotiation. • The contract is conditional on Ledjadja Coal completing construction of the 36 km rail link to the existing rail network. • The contract is also conditional on TFR completing its processes to determine a fair, proportional and equitable allocation of rail capacity to all interested parties from the Waterberg. If these are not completed by 31 December 2012, this condition is automatically waived and the above tonnage allocation becomes firm. wash plant with a 14 Mtpa run-of-mine (ROM) capacity. From this it will deliver 3 Mtpa of coal to the export market and another 3 Mtpa of domestic grade quality to Eskom. This is in line with its TFR capacity allocation agreement. Successful test burn results indicate Boikarabelo coal can be utilised with Eskom, and two Mpumalanga-based power stations have already been identified. “We want to increase our coal output substantially in Phase 2, increase annual capacity to 15 Mtpa, of which half will be allocated for domestic use,” Jury reveals. Development for the Phase 2 expansion is scheduled to commence three or four years after production commences. Jury notes that while ResGen may own one of the most prospective Waterberg properties (over 19 000 ha in total) within the entire coal field, beneficiation remains one of the most challenging project aspects. “Our overburden is small, between 20 and 25 m, and our average coal seam (with nine benches) thickness is 140 m – interspersed
with shale layers. Our current reserve of 745 Mt also only accounts for 35% of the total resource area, meaning Boikarabelo’s lifeof-mine is well beyond the average 20 or 30 years ultimately. “There is, however, a high degree of variability in the coal, with a high level of ultra-fines, meaning we must ensure the beneficiation process is optimised and best suited for the coal is critical. “Because this element of the project is so important, we have appointed two different South African engineering houses to provide us with two different front-end detailed designs based on different process schools of thought.”
Power, water and employment Power supply in the region is extremely limited and, as a result, ResGen has elected to develop its own power station as part of its overall project. “Our intention is to build a 45 MW (three 15 MW units) fluidised bed plant power station. Two comprehensive tenders have been
MD, Paul Jury on site
PRODUCTION PATH • • • • • • • • • • • • •
Lodge mining rights application: 3 Coal off-take: 3 CESC: 38-year contract Bhushan Steel: 20-year contract Defined transport solutions: 3 Designed infrastructure: 3 Mining right issued: 3 Project funding: Under way Commence mine construction Q4, 2012 scheduled Order mine fleet: Q4, 2012 Complete mine construction End 2014 Mine fleet delivery: Q4, 2014 Coal production: Q1, 2015
received to construct the plant over a twoyear period. “Our integrated water use licence has also been approved – and will see us utilise our own water from our own bore-field. We will not be a massive water consumer, however; as a modern mine, it will be contained within a closed circuit.” Once the mine is operational, ResGen will be responsible for the employment of 750 workers, including those employed at the power station. The company has every intention of fulfilling its target to employ an equal gender mix from surrounding communities such as Lephalale, who it will also train. Experienced mine and human resource managers have already been appointed.
Prestigious Projects in Africa
DEVELOPING ATTRACTIVE DIAMOND MINES
Slowly and thoroughly
AIM-listed diamond junior Stellar Diamonds may not have operational mines yet, but the amount of time and level of investment it is injecting into its two core diamond projects will ensure it delivers new world-class mines, CEO Karl Smithson tells Laura Cornish.
lobal diamond jewellery consumption is expected to achieve an annual growth rate of 5.6%, reaching US$128 billion (R1.04 trillion) by 2020. This, in turn, will help rough diamond demand to grow an average of 10.4% every year to reach US$40.8 billion in the same time frame. Coupled with such a promising outlook for the diamond sector is Stellar Diamond’s unfaltering commitment to its diamond project prospects. “We have over 12 years' of experience in West Africa’s Sierra Leone and Guinea, and an experienced core team on the ground comprising no expatriate geologists,” says Smithson. And despite the fact that both its core projects are building up towards pre-feasibility stages, it already employs and has trained 300 personnel. “The combination of the increasing diamond price and our investment and commitment to our projects will ensure we develop successful, profitable diamond-producing mines,” Smithson continues.
Inside Mining 09/2012
“And while our timeframe seems longer than most average mine development timeframes, we believe it is essential to be thorough and sure at all stages.” Importantly, all of Stellar’s projects already include small-scale process plants and despite their remote African locations, have sound and accessible infrastructure, and sufficient water. “Electricity may be our only challenge, but we have generators on site and acknowledge that power will make up at least 60% of our operational costs.”
SIERRA LEONE Tongo project – the most advanced “At present, we are working towards doubling the project’s inferred resource to above 1.2 million carats towards the beginning of this year’s fourth quarter. We will achieve this by drilling Dyke 1 to a 300 m depth and verifying the eastern extension of the kimberlite,” Smithson explains. Once this resource has been independently
ABOVE Bulk sampling of Droujba kimberlite pipe
verified, the plan is to double the resource again to a depth of 600 m. At the same time, underground trial mining will be initiated with the aim of mining a 10 000 t bulk sample, which should take approximately 18 months to complete. Thereafter, a fully fledged operational mine should take between 12 and 24 months to establish. “Our aim is to ultimately produce about 100 000 carats, of high quality, every year from Tongo,” Smithson notes. Perhaps the project’s close proximity to Koidu Holdings’ 180 000 tph kimberlite project, located some 60 km to the north of Tongo, might indicate an ‘additional vote of confidence’ in Stellar’s project. Koidu’s diamond grades place it among the top three of highest revenue per tonne kimberlite operations in the world. So much so that a leading diamond retailer, Tiffany & Co, has entered into an exclusive off-take agreement with the project.
Kono project Stellar Diamonds’ second Sierra Leonebased project, Kono, is temporarily on hold following a licence dispute announcement in April this year. Boart Longyear moving its rig and equipment onto the Tongo project
declaring 2.5 million carats to a depth of 360 m. “Ultimately, our intention at Droujba is to define a resource of over 4 million carats, with a contained value of over US$240 million,” Smithson notes. The current resource statement includes 1.3 million carats as part of an open-pit plan (to 160 m depth) and an additional 1.2 mil-
Current inferred resource
Current implied in-situ value (million US$)
12 month target additional carats (million carats)
12 month implied addition in-situ value (million US$)
Total target carats (million carats) Total target in-situ value (million US$)
“We are in a dispute with the Ministry of Mines over our Kono project permits; the ministry claims our licences are invalid. We are currently investigating political and legal avenues to resolve this situation,” Smithson explains. “Our next step at Kono will be to embark on a programme to drill out a 2 Mt resource, which we should be under way with already. Stellar Diamonds has done everything according to the law in terms of complying with the mining code and believes this issue will be resolved.” The company has spent some US$19 million on the Kono project to date, which includes underground trial mining. Despite the delays, the company has suffered no problems with the renewal of its nearby Tongo licence.
GUINEA Droujba project In March this year, Stellar Diamonds released an inferred resource statement for its Droujba kimberlite pipe project
lion carats comprising an underground mining portion (from 190 to 360 m depths). An additional 400 000 carats has not been included in the resource, which constitutes the area from where the open-pit portion ends and the underground portion starts. The next step, which started in June this year, includes the collection and treatment of a 2 000 t bulk sample from the pipe, which should contain about 1 500 carats. The first two of eight Phase-2 samples have yielded grades of 69.98 cpht and 109.59 cpht from a total of 383 t of processed material to date. Thirty stones of +1 carat have been recovered and include a 6.9 carat gem-quality stone. Smithson believes this project is two or three years away from reaching production status. He anticipates production will be about 400 000 carats per annum from the open-pit portion of the project, which should have a life of mine of between five and six years. The cash generated from the opencast mine will fund the project’s underground development needs.
ELECTRA Special Stand G21, Hall 6
ATLAS COPCO | EMPLOYEE DEVELOPMENT
A key priority for Atlas Copco Atlas Copco’s voluntary, confidential and free wellness and HIV/AIDS initiative has been running successfully for 10 years
well equipped to apply for vacant permanent positions at Atlas Copco. Ten graduates are currently in the programme. Visitors to Electra Mining are invited to Atlas Copco’s interactive stand for hands-on demonstrations and one-on-one quality interaction with the team. With innovative products and services, supported by skilled employees, Atlas Copco is committed to sustainable productivity, delivering sustainable solutions and optimising equipment availability and product operational life to increase customers’ operational efficiency and productivity – always placing customers as the centre of attention.
Hydraulic breaker breakthrough
Global industrial company Atlas Copco will focus on people, and more specifically employees, at this year’s Electra Mining exhibition.
he group firmly believes that employees are a company’s most valuable asset and therefore the most important investment a company can make. Striving to become employer of choice is in line with the Atlas Copco group’s vision to become and remain ‘First in Mind – First in Choice’ with its stakeholders. As a customer and service-driven company, employees must be motivated, committed, professional, highly skilled and well trained. But in order to ‘walk the talk’, Atlas Copco takes on the role as employer of choice for both internal and external candidates. As a Level 3 BBBEE contributor, the company not only appoints skilled people, but takes on the responsibility to upskill and regularly train employees to ensure that they are up to date with the latest technologies. Employee investment is multifaceted and includes training, skills improvement, creating career opportunities and encouraging internal upward mobility. In 2008, Atlas Copco joined forces with SKF to establish a state-of-the-art training
Inside Mining 09/2012
facility, the Atlas Copco Academy, based in Boksburg, Gauteng, which addresses a wide range of operator and technical training requirements. The facility offers apprenticeship programmes for between 100 to 150 candidates. Showing its commitment to local job creation, Atlas Copco has retained more than 60 out of the 70 apprentices who
“The significant increase in the power to weight ratio and the high efficiency of the latest generation Atlas Copco small (SB), medium (MB) and heavy (HD) hydraulic breakers translate to reduced investment and operating costs for lower overall cost of ownership,” says Neville Stewart, business line manager construction tools division. He explains, “Less hydraulic input power is required from the carrier while maximum impact performance is maintained which calls for smaller carriers and lower investment costs,” adding that less input demand from the hydraulic system to operate the breaker means reduced fuel consumption
Visitors to Electra Mining are invited to Atlas Copco’s interactive stand for hands-on demonstrations and one-onone quality interaction with the team qualified in its last training programme. The company also provides a graduate development programme whereby recent graduates from various disciplines, from engineering and marketing to SHEQ and finance, are recruited by Atlas Copco on numerous projects relevant to their field of expertise. The highly qualified graduates are
and resultant lower operating costs. “This makes our range of hydraulic breakers, which were developed in Germany, extremely efficient and suitable for a wide range of market segments including mining and quarrying.” Powered by a combination of oil and gas, the Atlas Copco breaker becomes virtually
ELECTRA Special The state-of-the-art Atlas Copco Academy addresses a wide range of operator and technical training requirements
independent from the hydraulic oil supply. Seventy percent of the impact energy is generated by the gas from the piston accumulator and only 30% by the oil supply from the carrier. The breaker, in combination with the internal control valve, is able to convert the required hydraulic input into more hydraulic output, thus improving the use of energy resources. The unique Atlas Copco Solid Body concept of the small hydraulic breakers integrates the percussion mechanism and guide system into one block of steel, including a 20% weight reduction; this unique design makes the product compact and easy to handle. This concept holds uncontested benefits for the customer such as flexibility, reliability, high productivity and low maintenance. The Solid Body generation is superior when working in confined spaces such as indoors or trenching. Atlas Copco medium and heavy hydraulic
ATLAS COPCO BUSINESS FOCUS Atlas Copco is a specialist designer, manufacturer and supplier of best-in-class mining and construction equipment, compressors, power tools and assembly systems, and a global leader in the delivery of sustainable industrial productivity solutions for over a century. breakers are particularly suitable for mine and quarry applications when: • loading is primarily done by wheel loaders • backhoe loaders or heavy-duty excavators
(with service weights upward of 150 t) are in use • loaded rock is very tough • secondary reduction is subcontracted
Individual growth through competence development
At Atlas Copco we believe that without individual growth, we wouldn’t be able to grow our business or solutions. Through competence development, we provide our employees with the knowledge that empowers and inspires them to deliver excellent customer service. This paired with individual responsibility, world-class challenges, internal career opportunity and great leadership, makes Atlas Copco an Employer of Choice. Learn more at www.atlascopco.co.za Visit us at electra mining mining • industrial • construction • electrical
africa 2012 Stand G21 Hall 6
ELECTRA Special • PROFILE CSA GLOBAL
Sinking African roots Global geological, mining and management consulting company CSA Global officially opened its Johannesburg-based African subsidiary company– aimed at better driving African project opportunities, writes Laura Cornish.
he addition of an African subsidiary office takes CSA Global’s worldwide presence to seven, providing it with direct exposure to nearly every sigross the nificant mining area across lobal globe,” says the CSA Global MD, Jeff Elliott. erThe company’s services cover all aspects of in, the mining value chain, tion from project generation source and exploration, to resource evelopevaluation, project development, operations and corporate advice. h, The local CSA branch, officially launched in
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June this year, already comprises four industry experts in the areas of resource estimation and consulting, and geo-statistics. With over 20 years of experience in the mining sector, principal resource geologist and former Gold Fields and AngloGold Ashanti employee Heather King will head up loca company. the local Despi the company having few current Despite projects in South Africa, Johannesburg is still considered the African capital and
Mount Mitaba, Tanzania
carries a long and well-established mining history. “It is the ideal place for CSA Global to build a regional presence to service the rest of Africa.” Considering the company’s first awarded project – in 1984 – was in Tanzania, and its African portfolio has been ongoing ever since, it is no surprise that CSA Global has invested in establishing a local presence.
“We like to establish real local presence and we see so much opportunity in Africa that this scenario will evolve in the mid-term future.” Jeff Elliott, MD, CSA Global
ELECTRA Special • PROFILE
The company currently has about 20 African mining projects under way, many of them generated through repeat business. “And we already have a diverse project range workload generated from our new office, so I predict strong growth from our new branch addition from now on,” Elliott continues. Until now, CSA Global has been managing its African portfolio from the UK and Australia; however, a number of additional driving factors led it to establish a local business office. “We prefer to bring on board local skills and expertise to better deliver on our African projects, for example in South Africa we gain expertise in the fields of diamonds, deep level gold mining, chromite and manganese. We also want to tap into the local labour markets to reduce our costs and retain a competitive cost offering to our clients.” Additional advantages include the reduction of travel costs, working in the same time zones and, generally, a contribution to further assist CSA Global’s strategic growth objectives across the world. Elliott anticipates that its local African model will, with time, reflect the business model it has established on other continents. Johannesburg will ultimately represent the primary African hub, hopefully growing and increasing annually in staff by about 20 people. This hub will then ultimately link to satellite offices based across Africa’s mining countries. “We like to establish real local presence and we see so much opportunity in Africa that this scenario will evolve in the mid-term future.” And why should the industry choose CSA Global? “Although we are global, we work
CSA GLOBAL’S SERVICE OFFERING
– From cradle to grave • Corporate services – valuations and expert reports • Project generation • Exploration programmes and reporting • Data management • Geological modelling • Resource modelling • Mining studies (optimisation and cash flow modelling, feasibility studies) • Grade control and reconciliation studies • Mine planning and scheduling • Mine closure planning.
ABOVE CSA Global head office reception BOTTOM Mobile office on Kenyan copper exploration project
CSA GLOBAL’S AFRICAN FOOTPRIN
collectively to solve clients’ problems; we have a pragmatic approach, are fit-for-purpose, commercially orientated and work to fit it in with our client’s corporate plans. We are independently owned and geologically focused, which means we ensure our clients’ project foundations are correct, which will guarantee all work that follows is successful,” Elliott outlines.
Republic of Congo
Rare earth elements, phosphate
Inside Mining 09/2012
ELECTRA Special Stand F7, Hall 6
REGAL BELOIT SOUTH AFRICA | NEW NAME FOR CMG
Same quality, products and services CMG Electric Motors South Africa, now proudly Regal Beloit South Africa, will be showcasing its entire product range at Electra Mining 2012.
egal is a specialist designer, manufacturer and trusted supplier of a comprehensive range of electric and worm geared motors, gearboxes, Vacon drives and related equipment to the diverse sub-Saharan industry. “The CMG Electric Motors Group was acquired by the Regal Beloit Corporation (RBC) in 2010,” explains CEO, Brian Campbell. “To become a more dynamic enterprise, to continually innovate and grow, and to reach
more people in more markets around the world, with the ultimate goal of making it ‘simple’ for customers to do business with the company, RBC, with years of industry experience, took the decision to streamline all of its corporate businesses and brands under one name, Regal. Regal reflects the mission to become a more focused, integrated and global company. “Although our name has changed, I can
assure all our customers that they can continue to rely on our high-quality products and the unwavering reliability of our service. As a global manufacturer of innovative and efficient solutions for motion control and power generation products, Regal supplies to diverse global markets, from heavy industry to high technology. This multinational corporation provides a global pool of cutting-edge technological resources and expertise to ensure all-inclusive drive and service packages to its customers. “Visitors to our stand at Electra Mining will have the opportunity to discuss the features, specifications and benefits of our comprehensive and impressive product and service offering,” concludes Campbell. Regal South Africa’s head office is located in Johannesburg and is supported by a country-wide network of branches.
Electric Motors, AC Drives, Geared Motors
A winning combination Building on a solid foundation of global resources, engineering ability and local industry knowledge, we offer a comprehensive range of class leading Electric Motors, AC Drives and Geared Motors suitable for virtually every application. As Regal, we continue to deliver excellent products and service supported by a full complement of spares and accessories.
Visit us at the finish line Electra Mining Stand E6 Hall 6
ELECTRA Special Stand D12, Hall 8
HAVER SOUTHERN AFRICA
LARGE VIBRATING SCREENS
Delivering to an evolving mining sector Haver Southern Africa has recently entered the Southern African market as a processing solutions provider and partner, and will be exhibiting its processing technologies at Electra Mining 2012.
t is common knowledge that global resources are dwindling – mines are delving deeper to find deposits and volumes have to be increased to achieve the same output due to decreasing grade quality,” says Joachim Hoppe, Haver Southern Africa operations manager. “As a result of more extreme mining and mineral processing, customers are demanding higher capacities from their equipment. Productivity remains any mine or plant’s number one priority,
Haver Southern Africa’s rugged screening machines are engineered and manufactured to handle widely varying or irregular input material feed rates, particle sizes and difficult-to-screen material
and they simply cannot afford failures and unplanned downtime. “We have noted a marked increase in the demand for large vibrating screens and our wide range, including 4-bearing, 2-bearing,
linear and eccentric-driven screens, operate reliably and perform efficiently and optimally, with little maintenance required under even the most stringent conditions. They are tailor-made to meet customers’ individual processing requirements. From gold, copper and iron ore to oil sand, our rugged screening machines are engineered and manufactured to handle widely varying or irregular input material feed rates, varying particle sizes – from fine to very course material, as well as difficult-to-screen material such as moist, sticky and/or very dirty materials”, he explains, adding that the screens are also ideal for limestone and hard rock processing, gravel screening and building rubble recycling. According to Hoppe, short lead times are just as important to customers as reliable and efficient performance. “We draw from the global resources and strength of the Haver Screening Group, which consists of three manufacturing facilities based in Brazil, Canada and Germany. Our designs are modular, manufacture is spread between these three workshops and assembly is completed in the closest location to the plant, a successful recipe for short lead times.” Few companies have the capacity to design vibrating screens of the size required on processing plants today. “The largest vibrating screens we have designed and manufactured have a 20 000 tph capacity, handling oil sand at a Canadian plant.” Hoppe says that it is so much more than just selling machines. “Our advisory service right at the beginning of a project is as important as our maintenance or refurbishment services. We always look for the best and most affordable option for our customers; we can sometimes refurbish for 30 to 40% of the cost of a new machine.”
Haver Eccentric Screens process high capacities of up to 5,000 tph. The completely balanced drive generates constant G-force to classify even difficult or sticky materials without introducing dynamic forces into your structure, minimizing investment into your building. For extreme applications, Haver Linear Screens process up to 15,000 tph. The exciter drive operates up to 50,000 hours without repair and has been designed to ease maintenance. The Linear Screens provide maximum screen surface to classify your materials while setting a new benchmark for reliability in your process. Haver Eccentric and Linear Screens redefine your choice in high-capacity screening.
ELECTRA Special Stand E25, Hall 6
MBE MINERALS SOUTH AFRICA | A BROAD TECHNOLOGY RANGE
Minerals processing of the future At this year’s Electra Mining exhibition, MBE Minerals South Africa – formerly Humboldt Wedag – will exhibit static scale models showcasing key elements of its broad range of technology.
ABOVE A USL-D double deck screen for coal sizing and washing LEFT The Batac jig technology offers excellent separation technology
hese will include its Pneuflot flotation, Batac jig, Romjig, Jones Wet High Intensity Magnetic Separator (WHIMS), Permos , a Palla Vibrating Mill, Teska HMS Separator and a wide variety of screens and feeders. In 2010, Indian turnkey engineering giant McNally Bharat Engineering (MBE) acquired German-based Humboldt Wedag Coal and Minerals Technology, including its South African subsidiary, and in the two years subsequent to this acquisition, MBE Minerals has made excellent headway in aligning its growth strategies with that of its new holding company. The MD of MBE Minerals SA, Johannes Kottmann, says the acquisition has expanded his company’s proprietary technology ownership, ideally positioning it to expand its presence across the entire SADC region through the introduction of new equipment, and technology and partnerships.
Inside Mining 09/2012
“We want to evolve into a complete technical solutions package provider, from technology creation to product manufacture and installation, along with all associated ancillary equipment. We’re much more than an equip-
Its Batac jig technology has been field-proven through extensive and diverse test work to deliver higher efficiency, huge economic benefits, better product quality, better machine availability and higher throughput rates. The prime advantages of this system are its excellent separation accuracy, relatively small size and comparatively low capital cost. Accuracy is achieved through electronic control of the air pulse generator and sensing of the thickness and densities of the material layers being separated.
“We want to evolve into a complete technical solutions package provider...” MBE Minerals SA MD, Johannes Kottmann ment distributor – we want to be recognised as a fully fledged process engineering company,” Kottmann says. The company’s Pneuflot technology is coming to the fore worldwide as a cutting-edge flotation technology, rapidly surpassing the popularity of conventional technology. The Pneuflot machine flotation cell improves product quality and the recovery, delivering lower capex and opex, as well as significantly lower wear costs and higher efficiencies.
Since its introduction to the marketplace, MBE Minerals SA’s Romjig has proved particularly suitable as a reliable and economical solution in processing coal. Extensive testing overseas has shown this jig to operate with an efficiency (imperfection) of I=0.08 to 0.1. Research indicates an overall reduction in the stone handled, as well as advantages resulting from the lower percentage of refuse in the washery feed. These include reduced wear on machinery and transporting equipment, less
grain degradation, less dust and slurry, and reduced consumption on flocculation and flotation agents in downstream fines recovery circuits. The robust Jones WHIMS offers a high throughput capability coupled with simple maintenance and lower energy consumption. The Jones is ideally suited to treating feebly magnetic minerals with a particle range from 20 microns up to 1 mm. Also on display as a static scale model, the Palla Mill offers the flexibility of being
suitable for wet and dry applications in primary and secondary grinding, and for pulverising materials of any hardness. “The Palla Mill has a major advantage over other machines of this type as it is capable of grinding more than 100 different materials, including a range of minerals and commodities previously considered unviable due to the costs involved,” Kottmann says. “Add to this ultra-fine grinding at maximum production with
ABOVE LEFT Pneuflot has positively demonstrated its efficiency in many mines around the world ABOVE RIGHT A Jones magnetic separator
the lowest expenditure on installation, grinding media and maintenance, and it becomes obvious why this vibrating mill has become a standard internationally,” he says.
MBE Minerals SA (Pty) Ltd A MBE Coal & Minerals Technology Group Company T +27 11 397 4660 F +27 11 397 4411
MBE Minerals is a leading global engineering company engaged in providing appropriate solutions in the areas of coal washing and minerals processing including separation, ﬂotation, crushing, milling and screening. Coralynne & Associates +27 11 422 1949
ELECTRA Special • PROFILE MARLEY PIPE SYSTEMS
Breaking big into mining In less than a year, plastic pipe system solutions specialist Marley Pipe Systems has established a significant footprint in the mining industry and is now working towards providing complete turnkey piping solutions, writes Laura Cornish.
aving established itself successfully in the civil engineering and industrial sectors over a number of decades, Marley Pipe Systems (Marley) announced its intention late last year to add the mining sector to its industry portfolio. Coupled with the completion of its first major piping project in the mining sector, the installation of a 50 km pipeline from DRDGold’s Ergo plant outside Springs to Crown, and the incorporation of a mining-specific pressure-pipe range, Marley has been making prominent marks in the industry ever since. Today, it has grown its mining client base substantially, with a portfolio that now includes Anglo American Platinum, AngloGold Ashanti, Gold One International and Harmony Gold, as well as clients
Inside Mining 09/2012
situated across the border including Katanga Mining in the Democratic Republic of the Congo. “We remain constantly focused on driving a solid reputation and building confidence with the mining sector, and want to be recognised as a company of substance,” says Peter Ker-Fox, Marley infrastructure sales and marketing manager. Marley offers a full HDPE and uPVC range – unique in the piping industry – enabling it to provide fit-for-purpose solutions. The company also provides the required fittings and a large variety of valves. Having so quickly established a significant project pipeline in the mining sector, supplying its wide range of piping products to the sector, Marley’s strategic focus for the future will be to provide turnkey innovative
ABOVE Marley 500 mm HDPE pipe being installed on site BELOW Marley PVC Pipe
ideas and piping solutions to the sector. “More and more clients are indicating a preference for single-source suppliers to provide installation services as well. While we have always offered this to our clients via a subcontractor, we are investigating the benefits for ourselves and how best to offer it to our clients, enabling us to achieve our goal of becoming a complete turnkey piping supplier,” Ker-Fox continues. Already the mining (and industrial) sectors account for about 60% of Marley’s infrastructure business, making it a crucial business component. Considering that sectors like civil are currently repressed, it also holds a lot of promise for future growth. “The challenge is to keep our growth momentum going without compromising on the service and quality our customers have become
ELECTRA Special • PROFILE
The challenge is to keep our growth momentum going without compromising on on service and quality
accustomed to. We have already achieved record sales months in May and July this year,” Ker-Fox reveals.
Noteworthy projects and accomplishments In April this year, Marley was awarded the contract to supply 11 000 m of 450 Class 12 mPVC piping to Harmony Gold’s Free State-based Saaiplaas tailings operations. “The pipeline, which was delivered in June and is already installed, will transfer water between tailings dams,” explains Jason Tannous, Marley North West area manager. “We are particularly proud of this project, and the subsequent relationship we have established with Harmony Gold. Various business units within the Harmony stable visited our Nigel manufacturing facility to perform plant audits and ensure we BELOW RIGHT Marley HDPE pipes BELOW Marley 500 mm PVC pipe on site at Saaiplaas tailings operation
complied with their stringent quality and service requirements. This not only indicated the client’s confidence, but showcases the levels of quality that suppliers must meet to secure work with Harmony,” Ker-Fox notes. Piping is a vital component in tailings dam management and recovery operations, and as such, Marley has also established a secure relationship with Fraser Alexander, which specialises in tailings dam projects. “We have successfully completed numerous, diversely different projects in the past year with this reputable company,” Tannous notes. One of Marley’s current focus areas is working with engineering firms who handle turn key projects. Towards the earlier part of this year we supplied a 4 km x 630 mm & 500 mm HDPE pipeline to a local engineering firm, which designed a diamond processing plant for Octea Mining’s (formerly Koidu Holdings) Koidu kimberlite project in Sierra Leone. What
ABOVE Marley HDPE pipe being used as a liner for the DRD Gold Project
makes this project so momentous for Marley is that in addition to the piping supply contract, we also supplied the client with HDPE butt-welding machines, which are used for piping installation. We also sent a Marley employee to site for eight weeks to train the client on how to use the machines,” Tannous describes. In addition, Marley also supplied all the HDPE fabricated fittings and piping for the plant itself. In July 2012, Marley also completed the supply and delivery of 8 km of piping to Richards Bay Minerals, which included specialised stubs and flanges. “We had to supply pipes of 24 m in length, making logistics a challenge. For Marley to establish a recognised brand, we must ensure we can meet client requests and specs, even if it requires incurring additional costs or challenges.”
Inside Mining 09/2012
ELECTRA Special Stand P20, Hall: Outside Stand A18, Hall 6
MULTOTEC | AN EXCITING PRODUCT SHOWCASE
Inside and out Multotec Group’s presence at Electra Mining Africa will reflect its current marketing theme – ‘The right ingredients for the perfect mix’ – with a comprehensive showcase of process and materials handling equipment, services and technical know-how, as well as existing, new and value-added technology.
he group will be exhibiting from a 220 m² indoor stand, as well as an outside stand adjacent to Hall 6 featuring several working demonstrations from its equipment line-up. Product experts will be on hand for one-on-one information sessions and to demonstrate the group’s technical capabilities. Representatives from Multotec’s extensive field service maintenance crew, offering 24/7 maintenance services throughout South Africa and moving into Africa, will also be available for discussion with interested parties. “We look forward every second year to Electra as an ideal opportunity to build relationships with new and existing customers,” Multotec Group’s Bernadette Wilson says. “We’re going all out to prove that we’re a young, energetic, reliable and highly innovative company to do business with.”
Never seen before
TOP The Multotec CX1200 fine coal centrifuge ABOVE The Multotec Teepee screen panel suitable for highcapacity dewatering applications LEFT A 20 tph Multotec spiral pilot plant
Inside Mining 09/2012
Never seen before at the show will be a working demonstration of Multotec’s self-driven trommel, a well-proven trommel for high capacity screening applications, as well as the latest version of the company’s sievebend, manufactured from HDPE. This corrosionand abrasion-resistant sievebend presents a lightweight and cost-effective alternative to the steel version. The stand will also feature a range of panels that are process specific in their application. The revolutionary Multotec polyurethane Teep Teepee panel will be displayed. Injection-moulded Injection-m rubber screen panels pane will be shown for the first time. The process team wil unveil another will new product at Ele Electra: Multotec’s new ccast iron CL115 cyclone, developed specifically for the coal industry to combat the tramp iron, traditio ceramic linwhich is damaging to traditional ings. The existing Multotec AA165 cyclone, areas will make ansuitable for high-wear areas, other appearance this year, alongside a fully operational mobile pilot spirals plant, differentiated for its application to heavy minerals. This is a simple plug-and-play container plant that makes for easy shipping. Multotec’s Cy-i suite of cyclone sizing and selection software suite, developed to equip customers with a scientific approach to making the initial selection of a cyclone for any given application, will also be demonstrated.
ELECTRA Special R&D â€œWeâ€™re investing in continuous research and development (R&D) that onal embraces computational mulafluid dynamics simulations, pilot plant and online ove the metaltest work to improve lurgical performancee of our process equipment,â€? Wilson says. â€œOur ongoulted in several ining research has resulted novations across the board and we will showcase some of thee results of the latd this year. est R&D on our stand elopments is a proâ€œAmong these developments totype pressurised slurry line sampler that is poised to replace the traditional off-take sampler. In addition, changes have been introduced to the Multotec overbelt magnetâ€™s power supply and transformer unit, and further changes are in the pipeline to make the unit more cost effective to our customers.â€? The latest version of the companyâ€™s CX1200 fine coal centrifuge joins the line-up, with a focus on its capabilities in the coal arena. Multotecâ€™s rubber offering is focused on the high impact resilience of rubber to benefit applications subject to impact of material. A range of rubber wear components will be exhibited, including a robust heavy-duty lifter bar that delivers long life. A range of fit-for-purpose rubber grate plates suitable for a broad spectrum of customer needs will form part of the display, together with a new magnetic wear plate, sold under license to Multotecâ€™s sister company Tema, based in the US, featuring an advanced liner design that boosts plant efficiency. Wear-resistant ceramic liners will be showcased using an innovative model that displays all the various liner applications in a plant. Mato Products South Africa, a partnership between Multotec and Mato Germany producing industry-leading conveyor belt fastening solutions, celebrates its 25th anniversary this year and a delegation from this German company will be visiting the stand to celebrate the event. As part of its social economic development programme, Multotec has engaged Vuka Designs, a welding company owned and operated by previously disadvantaged South Africans, to manufacture decorative welded products that will form part of the standâ€™s decor. â€œWeâ€™ve got some really exciting treats
planned for f our visitors this year, so we encour encourage all existing and potential customers to register for EMA online prior to th the opening day, for ease of entrance aand to qualify them to enjoy an unforge unforgettable Multotec experience,â€? Wilso says Wilson. LEFT A Multotec 165 cyclone suitable for high wear areas RIGHT A Multotec self-driven trommel
for the perfect mix
Multotec, a leading mineral process solutions provider to the mining and mineral beneďŹ ciation industries, partners with customers for perfect equilibrium between the life of equipment and process effectiveness in every individual customer application. Our value-added products and extensive application knowledge have established our global reputation for providing optimum technical solutions and the highest levels of support through consulting services and ďŹ eld service teams.
Indulge yourself in the Multotec experience 4FQUFNCFSt)BMMt4UBOE" 5FM tNBSLFUJOH!NVMUPUFDDP[B www.multotec.com
ELECTRA Special Stand 8D, 18
TOMRA SORTING SOLUTIONS | COMMODITY SPECTRUM
X-ray screening, sorted Sensor-based sorting solutions provider for the mining industry, CommodasUltrasort, is the mining division of internationally renowned Norwegian-listed Tomra Systems ASA, and will exhibit at Electra Mining under its new name Tomra Sorting Solutions.
omra Sorting Solutions South Africa’s general manager, Lütke von Ketelhodt, says he is pleased with the name change as it unequivocally identifies his operation as part of the one of the world’s biggest and most technologically advanced sensor-based sorting companies. “We are part of a financially powerful group, which not only emphasises the importance of ongoing research and development, but has the muscle to make this a reality. As a result, we are constantly ahead of the game with respect to new sensors and improved technical designs of the equipment and the mines we are supplying to are proving this to be the case,” Von Ketelhodt says.
Chrome TSS’s X-ray Transmission (XRT) sorting technology is producing better than
The PRO Secondary XRT unit and X-ray source
Inside Mining 09/2012
expected results in the separation of lumpy chrome ore from waste rock at a chrome operation situated on the western limb of the Bushveld Complex. Its XRT chute sorter has been operating on a full production plant at the mine processing 70 tph at >90% availability. After blasting and trucking, the ROM is crushed and screened, and the -60 mm to +20 mm material is delivered to the XRT sorter, while the rest of the material is transferred to a conventional beneficiation plant. The feed grade into the XRT sorter
averages approximately 32% chrome and the process upgrades the saleable product to 36% or better, at 97% efficiency.
Diamonds Another TSS success has been on one of the largest diamond mines in the world based in the Southern African region. Between March and August 2011, a pilot study was conducted on a prototype XRT belt sorter, feeding material with various throughputs
ELECTRA Special and size ranges, and producing a total recovery greater than 98%. The mine was seeking a new method of recovery for large diamonds, prior to tertiary crushing. The main advantage of the XRT technology in this application is that it sorts on an atomic density rather than according to physical characteristics or properties such as relative density and luminescence. As the luminescence properties are not always consistent in diamonds, a technology was required that would recognise all diamonds, regardless of their physical properties. “Our XRT is able to see the atomic makeup of each particle going through the detection zone of the machine. A diamond, which consists of covalently bonded atoms forming so-called ‘diamond molecules’, appears in a distinct light-grey X-ray image,” explains Von Ketelhodt
WHO IS TOMRA SORTING SOLUTIONS? Tomra Sorting Solutions provides sensor-based sorting solutions to the mining industry. Over the past 20 years, it has installed more than 10 000 sensor-based systems in more than 80 markets worldwide. This includes more than 180 sensor-based sorting machines in mining and mineral processing applications across the globe, successfully sorting a variety of minerals and ores including coal, industrial minerals, platinum, gold, diamonds and tanzanite. TSS products are incorporated into three main product lines: the ROM series of belt sorters, suited to coarse primary ROM material up to -300 mm; the Industrial Processing (PRO) Series, comprising chute-fed free fall sorters for primary, secondary and tertiary ROM material; and the Gemstone (GEM) Series, comprising sophisticated wet-dry sorters for diamonds, emeralds, tanzanite and other gemstones.
also improved the coal calorific value from 17.9 to 25.0 Mj/kg and simultaneously reduced the sulphur content. “In the process we also proved that our PRO Secondary XRT sorter is capable of processing up to 150 tph of coarse raw coal, effectively removing the bulk of the contaminant stone in the raw coal with all the associated benefits.”
Coal On one of South Africa’s leading coal mines, the company’s PRO Secondary XRT sorter reduces the ash content of coarse raw coal from an average 37.3 to 17.8%. The sorter
Robust and environment-friendly No slurry is produced with XRT technology, resulting in reduced groundwater pollution due to acid drainage and salt accumulation
in water circuits. It is also less capital intensive because it does not require the extensive infrastructure and water handling requirements associated with dense medium separation. The TSS sorting technologies are also relevant to today’s mining conditions. “Increasingly we face challenges such as low-grade ore reserves, high energy costs, water shortages and stringent environmental legislation. Sensor-based sorting is a very significant innovation in mineral processing technology and upfront beneficiation.”
“DON’T WASTE ROCKS!” How about putting less effort and energy into your Come and see us:
process and at the same time increase your output?
Electra Mining Johannesburg, South Africa 10–14 September 2012
Find out how TOMRA’s sensor-based sorting systems
will get you ahead of your competitors.
Don’t waste time: www.tomrasorting.com
ELECTRA Special Stand F30, Hall 6
THE CORD GUARD AND MORE
Conveying the latest engineering feats The supplier of Goodyear-branded engineered rubber products, Veyance Technologies, will be showcasing its latest engineering feats at this year’s Electra Mining 2012.
n line with the event’s mining, construction, power generation and industrial themes, Veyance will highlight its Conquest, Solar-Shield as well as its Flexsteel, Plylon, PVC and PVG conveyor products. “Additionally, our LLR, a low rolling resistance belt that saves energy and reduces costs, will also be on display,” says Paul van Zyl, marketing manager at Veyance Technologies Africa. “The main showcase will be our Cord Guard XD conveyor conditioning monitoring system, which rapidly detects rips and is programmed to stop the belt to minimise any resulting damage.” Veyance will also display its conveyor services range, which includes hot and cold vulcanising, belt repairs, pulley lagging, rubber conditioning, condition monitoring, belt inspections and conveyor maintenance. “Represented on the show stand will also be a variety of world-class industrial hoses, including a highly reinforced hose for handling underground rock dust applications (Tunnelcote), as well as our power transmission products range,” concludes Van Zyl.
ELECTRA Special PILOT CRUSHTEC | DIAMOND DEFERENCE
Crushing without compromise The resurgence of the alluvial diamond mining industry is boosting the sale of screening equipment across the African continent.
ne of the equipment ranges benefiting from this resurgence is the Terex Finlay products, supplied by local crushing and screening specialist Pilot Crushtec. “These machines are made for Africa. They’re mobile, require little maintenance and are very reliable,” says Steyn’s Diamante, owner, Schalk Steyn. He operates a sizeable fleet of Terex Finlay equipment, including six mobile Terex Finlay 883 heavy duty scalping screens and one Terex Finlay 984 3 deck horizontal screen. The company bought its first Terex Finlay product more than seven years ago, and found it to be ideally suited to the business of alluvial diamond mining. “Right from the beginning we found the equipment to be compatible with our existing plant and systems, and the versatility of the Terex Finlay 883 mobile scalping screen means we can do in-pit screening, which saves a lot of money,” says Steyn. Large, as-dug material can be placed by excavator directly onto the heavy duty apron feeder of the Terex Finlay 883, which then feeds the rock onto a doubled deck screen fitted with heavy-duty, replaceable
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tyres on either top or bottom decks. According to Pilot Crushtec director of sales, Graham Kleinhans, versatility and cost effectiveness is definitely the Terex Finlay strong suit. “If you mine, you have to rehabilitate the land you have disturbed and in the case of alluvial diamond mining, this means river beds containing the ore. Even while it screens, the Terex Finlay 883 is engaged in the rehabilitation process, as its oversize conveyor automatically returns reject material, even boulders, back into the ground.” Steyn’s Diamante is currently mining a stretch of land between the towns of Prieska and Douglas in the Northern Cape province, which Kleinhans says is where a Terex Finlay comes into its own. “Firstly, Terex Finlays are diesel powered, so they can operate free of the restrictions associated with electric power. Secondly, even under rugged conditions, they can comfortably screen around 400 tph. Being tracked, they can also be easily walked from one screening section to another,” says Kleinhans. From time to time the operation also uses the Terex Finlay 883 screen in conjunction with the Terex Finlay 984 3 deck horizontal
Steyns Diamante recently added another Terex Finlay 883 screen to its already impressive fleet of equipment
screen to produce five products at high capacities. Steyn believes that much of the Terex Finlay’s proven reliability comes down to its basic design. “It is a very mechanical machine and does not have complex electronic controls, which can be a problem when working under African conditions.” Steyn’s business acquired three 883 mobile screens between November 2011 and January 2012. At a cost of approximately R2 million each, this shows he has genuine faith in Pilot Crushtec’s ability to back up its products as Douglas is nearly 700 km away from the Pilot Crushtec factory in Jet Park, east of Johannesburg. “Their support is excellent and so is the service. If we need a part, Pilot Crushtec gets it to us overnight or even over a weekend. Their management and sales engineers visit us regularly and we regard them as the market leader,” Steyn concludes.
ELECTRA Special Stand J20, Hall 6
SEW EURODRIVE | X-SERIES INDUSTRIAL GEAR UNITS
Size matters SEW Eurodrive’s robust helical and bevel-helical gear units, part of the X-Series of industrial gear units, cover a torque range of 6.8 to 475 kNm and are on show at this year’s Electra Mining exhibition.
erman drive automation specialist SEW Eurodrive produces the X-Series industrial gear units on an independent platform. The gear units feature finely graduated size, variable installation and a wide variety of modular options. The extremely large gear ratio of 6.3 to 450 kNm is evidence that with its X- Series, SEW Eurodrive meets all the requirements for a complete, comprehensive range of industrial gear units. When it comes to helical and bevelhelical gear units, nearly any mounting position or shaft arrangement can be implemented. The X-Series’ finely graduated size and high-power density delivers significant savings in terms of weight and cost. The large amount of predefined accessory equipment creates flexibility in terms of adjusting the unit to each respective application. This includes a wide range of modular options such as motor adapters and mounting flanges, backstops and cooling systems as well as sealing systems for the most varied environmental conditions. One main area of application for SEW industrial gear units is conveyor systems. In this context, the gear units perform reliable service in driving conveyor belts and bucket elevators for the horizontal and vertical transport of bulk materials and packages. They also run the travel and hoist drive on cranes or serve as a drive with reinforced bearings for mixers and agitators. X-Series industrial gears have proven
Inside Mining 09/2012
particularly popular in the mining industry . SEW Eurodrive compiles drive packages for the customer that include components
feedback probe, the DUO Oil Analysis sensor and the DUV Vibration Analysis sensor. Also fitted in the unit is an integral one-
SEW Eurodrive compiles drive packages for the customer that include components such as industrial gear units, a motor, couplings, brakes and steel frames such as industrial gear units, a motor, couplings, brakes and steel frames. In this case, customers benefit because they can obtain the complete, fully assembled drive package from a single source.
The X-Series unit is designed for the mining industry and will be on show at Electra Mining
Of particular interest to Electra Mining fair goers will be X3K helical bevel unit designed with the mining industry in mind. It includes the latest condition monitoring equipment in the form of a temperature
directional backstop bearing, which allows allow for a more compact design of the geared motor. An auxiliary drive was fitted to allow for easy maintenance when the drive need needs edging. This type of set-up allows for better bette energy efficiency during maintenance when the smaller auxaux iliary drive can be used instead of the larger large industrial gear gearbox. This type of o unit would suit a bucket-elevator bucket-elevatortype set-up. set-up. In addition, a mixing unit will wil be on display in the form of the smaller MC Series Serie of industrial gea gear units from SEW Eurodrive. It is fitted fitted with an extended bearing distance and SEW motor. The extended bearing distance assists assist in handling the higher torque loads that tha come standard with mixing applications. A drywell oil seal is also included in this unit. The South African arm of SEW Eurodrive has a dedicated industrial gear unit factory in Nelspruit that services the local market with custom-designed units. A large local stockholding makes for shorter delivery times and more flexibility.
Geared Motors \ Drive Electronics \ Drive Automation \ Industrial Gears \ Services
We drive the mining industry
SEW-EURODRIVE offers innovative drive solutions for all applications in the mining industries. All SEW-EURODRIVE products and systems make the best use of the space available around the machine and ensure great ďŹ‚exibility and reliability. Minimum maintenance and simple operation ensure that you will operate machines and equipment efďŹ ciently from the very beginning.
Thanks to the modular design and countless combination options, all drive engineering components can be replaced quickly, if the need arises. From gravel mining to the excavation of gold, platinum, coal and diamonds - we put the drive into all facets of the mining industry.
SEW-EURODRIVE - Driving the world.
Come and visit us at Electra Mining. Live in Hall 6, Stand J20 at the Nasrec Expo Centre in Johannesburg on 10th - 14th September 2012. We look forward to seeing you there!
Tel: +27 11 248-7000 Web: www.sew.co.za
ELECTRA Special Stand J20, Hall 6
OSBORN | ROBUST AND RELIABLE
Delivering what the industry needs Osborn Engineered Products, a name synonymous with robustness and reliability, has the confidence of 90 years’ experience to back its product range. From design concept and manufacture to installation and commissioning, Osborn provides the world's mining industry with a full range of crushers, feeders, screens and conveyors.
atering for all mining and quarrying equipment requirements, from the primary tip to the milling discharge circuits, Osborn offers a complete solution. The South African company recently supplied equipment worth R14 million to a new mine in the Northern Cape, situated between Black Rock and Sishen. Osborn product specialist Francois Scott elaborates: “We secured this order, for the new manganese mine, based on the number of machines that we already have operating in this area.” According to Scott, Osborn has supplied eight machines into this part of the country over the past 12 months, primarily for manganese production. “Some 90% of all the machines operating in the region aree Osh the born’s.” He says that this, combined with shers fact that this customer has Osborn crushers
RIGHT Exciter driver screens for Petra Diamonds BELOW Osborn apron feeder and vibrating grizzly feeder installed in a manganese application
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operating successfully at another site, led it back to Osborn for this latest order. The order included an apron feeder, vibrating grizzly feeder, jaw crusher and an Osborn 57SBS Gyrasphere cone crush-
screens from Petra Diamonds. The screens will be employed at the diamond miner’s Cullinan operation, where a new tailings reclamation plant is being set up. This order comprises six Osborn IFE screens and
Osborn’s IFE Screens are designed for heavy-duty to extraheavy-duty screening er. The installation and commissioning were also undertaken by Osborn. Also included in the equipment supplied was a BTi MRHT25BXR50 stationary Rock Breaker System, which is perfectly suited to typical Northern Cape manganese hard applications. rock applications. recentThe company also ly secured an order for seven
one Osborn OBEX single deck screen. Osborn product manager, Emile Oosthuyzen, explains that Osborn’s IFE Screens are designed for heavy-duty to extra-heavyduty screening, and feature a gearbox drive that is driven via a cardan shaft from an electric motor, in order to t generate more G-force for the weight of the machine. Over the years, these tou tough, hard-wearing screens have made ttheir mark at operations lik like Kleinkopje collie liery, Iscor’s Sishe en, Zimbabwe’s W Wankie colliery, E Empressa Minera C Copper mine in C Chile and Namak akwa Sands, ree flecting the diverse app applications of this rang of screens in range prod products ranging from coal and copper to iron ore, heavy mineral sands and diamonds. Osborn is a member of the Astec Industries group of companies, an American manufacturer of plant and equipment for aggregate processing, asphalt road building, pipeline and utility trenching. Through Astec, Osborn now offers an imported range of construction equipment, including asphalt road construction machines, trenching technology and directional drills.
ELECTRA Special Stand A18, Hall: Outside
SANDVIK | THE PERFECT OPPORTUNITY
Showcasing new technologies Global high-tech engineering group Sandvik will once again be among the top global exhibitors to participate at Electra Mining 2012, where it will be introducing new technology alongside a selection of its core products.
his is a particularly special year for us as Sandvik celebrates its 150-year anniversary of global business,” says Alice Ward, Sandvik marketing and communications manager for Africa. Originally known as SandvikJernverk, the company entered the African market through the development of rock drills and its partnership with Atlas Copco in the 1940s. A production facility was established in South Africa as early as 1948. Sandvik has always worked with the most advanced technology of its time.
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The group’s cluster of expertise has grown stronger over the decades and today it has patents, drawings and expertise pertaining to hundreds of thousands of advanced products in alloyed steel, titanium, cemented carbide and ceramics. It’s this core expertise in metals and materials that is the root of the company’s global success.
its construction range, the DI550 construction drill and the DS210L-M low profile mechanised roofbolter. The new DM300 mobile bolter offers semi-automated operation, reducing the operator’s contact with the drilling operation to a bare minimum and therefore significantly minimising the risk of hand injuries. The DM300 has four drill rigs in
Highlights Mining equipment featured on the stand will include the company’s new DM300 mobile bolter, the DR580 surface mining drill, a compact hybrid crusher and, from
The Sandvik DR580 surface mining drill is ideal for drilling production, pre-split, pioneering, dewatering and reverse circulation in-pit grade control holes
Mining expertise for your benefit Operating in the mining industry is so much more than just about great equipment. It is not just about equipment that achieves great productivity. It is not just about equipment that offers increased outputs. It is not just about equipment that offers cost effective performance. Sandvik equipment can offer all this, but with Sandvik it is more about what lies behind that equipment. It is about the ongoing research and development. It is about the support in the field. It is about the people. And most importantly, it is about you - our customer. SANDVIK MINING For enquiries please contact Tel: +27 (0) 11 929 5300
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Visit us at stand OSA18 at Electra Mining Africa 2012
GLOBAL GRAPHIX +27 (0) 11 053 6190
Innovating the future
ELECTRA Special The Sandvik DM 300 mobile bolter offers semi-automated operation, reducing the operator’s contact with the drilling operation to a bare minimum and therefore significantly minimising the risk of hand injuries
the front of the machine, enabling two operators to fit four bolts in a row in less than half the time that a twin boom bolter would take to install four bolts in a row. This machine is able to do side wall drilling with two optional drill rigs fitted to the rear of the machine. The DR580, a diesel-powered DTH crawler-mounted surface mining drill, is ideal for drilling production, pre-split, pioneering, dewatering and reverse circulation inpit grade control holes. This drill boasts the highest air pressure in its class to achieve maximum drilling performance. The cab is ergonomically designed, providing a comfortable cabin that operates on a swing
The Sandvik DS210L-M is currently the only low profile mechanised roofbolter on the market
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concept to give superior visibility and enhanced safety. The operator also benefits from the ability to achieve precise positioning, an easy drill set-up and greater accuracy. The heavy-duty DR580 is manoeuvrable
completely mechanised, no one is exposed to unsupported ground during the drilling and roofbolt installation processes. The company’s DI550 construction drill is ergonomically designed for productivity and user comfort, and is being hailed as the first of the new generation of down-thehole drill rigs. This drill features a 324 kW diesel engine and a 24.4 m3 compressor air flow at 24 bar pressure, making the machine a perfect match for the 4-inch and 5-inch DTH hammers. This careful match of power and hammer size makes the rig uniquely productive, reducing fuel consumption and keeping operating costs as low as possible. Cost effective machine performance is further enhanced by other advanced features such as active diesel RPM control, optimised diesel RPM level during drilling and active control of compressor running temperature.
The Sandvik hybrid crusher is known for its compact design and minimum generation of unusable fine material and stable, and offers ease of maintenance. The Sandvik hybrid crusher is known for its compact design and minimum generation of unusable fine material. The DS210L-M is the only low profile mechanised roofbolter on the market at the moment. Personnel safety is the major benefit with this machine; since the roofbolt drilling and installation processes are
On top of high performance, simple and comfortable machine operation is a key feature of the DI550. With a modern, accurate control system and simple icon displays and comprehensive service information, the new DI550 enables seamless cooperation of man and machine. The rig’s modern, over-pressurised ROPS and FOPS certified cab with advanced ergonomics, efficient air conditioning and excellent visibility further adds to operator comfort. The large windshield comes with a strong safety bar that is easy to open for cleaning. An efficient dust collector with non-stop cleaning decreases the amount of dust emissions to the environment and improves filter lifetime, reducing the need for maintenance. Other features that translate into easy maintenance and low downtime include the engine compartment’s open layout, easy cooler cleaning, modular compressor control system and simplified electric system. All daily maintenance points are located at ground level to simplify the process and improve safety of service personnel. A fast fuel-filling option and large fuel tank further cut costly downtime.
BLUE IS THE NEW GREEN
Coralynne & Associates +27 (011) 422 1949
0861 00 ZEST (9378)
To find out more scan the code or visit: zest.co.za/sustainability
ELECTRA Special Stand E18, Hall: Outside Stand G30, Hall 6
ZEST ELECTRIC MOTORS | COMBINED STRENGTH
It’s the whole package The combined strength of the Zest WEG Group of companies will be showcased at the Electra Mining exhibition, with an integrated display of products and expertise that reflects the group’s culture of quality and service excellence across the board.
est Electric Motors’ highly customer-centric approach –24/7 support, technicians deployed throughout the country and into Africa, as well as internal and external sales support – has effectively permeated into Zest WEG Group companies and today it offers the same magnitude of support,” says Jamie Wilson, marketing manager of the Zest WEG Group. “The Zest WEG group is an acknowledged leader in the supply of electric motors and drives, motor control panels, generator sets, energy solutions, and ancillary products and services. After marketing internationally renowned WEG products for the past three decades, we’ve enjoyed the full backing of WEG as Zest Energy's in-house substation engineering department designs, procures and constructs complete substations
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our holding company since 2010.” This will be Zest’s 16th consecutive appearance at Electra. “A team of sales engineers will be on hand to present our equipment and answer visitors’ questions. We’re also setting up a mock-up of our small works division in action, which includes Zest WEG Group’s learnership programme.”
Zest Electric Motors Expressing the Zest WEG Group’s focus on green energy efficiency, Zest Electric Motors will showcase the motor drive combination of the WEG W22 electric motor coupled with its WEG CFW11 variable speed drive technology. WEG’s innovative three-phase W22 motor, available locally from Zest Electric Motors, provides an energy-efficient solution to reducing industrial energy consumption. The
WEG CFW11 series of inverters includes state-of-the-art technology for three-phase induction motor control and was developed to boost customer productivity. Also on show at the Zest WEG Group stand will be the WEG SSW7000 medium voltage soft starter, which provides stateof-the-art technology start/stop control and protection for three-phase medium voltage induction motors in the 2.3 to 6.9 kV range. Zest WEG Group’s switchgear division will be introducing its new range of miniature contactors and motor protection circuit breakers with spring loaded terminal connection. Also on show will be the recently upgraded range of DWA moulded case circuit breakers along with a full range of capacitors and also WEG’s state-of-the-art SRW01 smart relay. The WEG W22X flameproof motor in the W22 mould will be exhibited on
ELECTRA Special the stand to highlight the importance of its classification that includes gas groups IIA, IIB and IIC. Supplied in frame sizes from 71 and upwards, these ATEX/IECEx certified motors are designed to cope with the rigours of aggressive and explosive atmospheres, while delivering the added benefits of high efficiency, (IE2/IE3 energy efficiency rating), minimised noise, vibration and low operating temperature for increased reliability and safety.
Zest Energy Zest Energy is experiencing robust growth across the African continent in three key energy generation arenas: power generation, substations and cogeneration. The Zest Energy team will be at Electra to engage with engineers specialising in substation and reticulation projects. Its solutions are proving comprehensive, innovative and cost effective.
Shaw Controls Shaw Controls, a manufacturer of motor control centres, portable containerised substations and various other electrical panels, has invested R25 million to date in a full-scale company-wide expansion project that has streamlined processes and systems across the board, moving the company closer to becoming South Africa’s number one motor control centre and container substation manufacturer. New developments include a new 1 000 m2 in-house container conversion yard that puts the company at the forefront of container conversions on the continent. Having a dedicated facility makes it possible to conduct preliminary preparation work on stock containers, allowing Shaw Controls to expedite new orders very quickly.
EnI Electrical In recent months, EnI Electrical, a specialist electrical, instrumentation and control systems construction company, has secured significant orders in mining hotspots across the continent, with most of its work being conducted beyond South Africa’s borders. A major factor in the company’s success is the Zest WEG Group’s collective robust relationships with customers operating in Africa, which has yielded many package deals, stimulating growth for all members of the group. EnI is currently at work in Tanzania, Zambia, Ghana, Mozambique, Namibia, Mali, Burkina Faso, the Democratic Republic of the Congo, Zimbabwe and South Africa.
IMS Cape Cape Town-based IMS, specialist in mobile power plants, will be exhibiting a locally built diesel generator at Electra Mining Africa this year. As Cape Town’s oldest and largest generator set manufacturer, IMS Cape has a reference base which goes back more than 30 years and the company can list many of South Africa’s major corporations among its customers.
Striving for a paperless stand “For the first time at Electra we will be making the entire collection of WEG, Zest and affiliated product brochures and tools available in CD format,” says Wilson. “Visitors will be able to utilise interactive audio-visual interfaces, guided by our sales force, through the interactive use of iPads and large flat screen displays. In keeping with this year’s green
ABOVE Motor control centres being built at Shaw Controls BELOW Zest Electric Motors will showcase the motor drive combination of the WEG W22 electric motor coupled with its WEG CFW11 variable speed drive technology
focus on sustainability and energy efficiency, we’re striving to achieve a paperless stand. Whatever information visitors require will be emailed to them in pdf format. “Our overall theme this year reiterates our ‘passion through our people’ drive, featuring graphic displays from our advertising campaign. We want to let more and more people know that we are so much more than a products company. We’ve evolved into a solutions company with an immense depth and breadth of skills and experience.”
Racking and cabling at Great Basin Gold's Burnstone gold mine
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ELECTRA Special BARLOWORLD | A NEW CRUSHING BENCHMARK
Unveiling the new Lokotrack LT120 mobile jaw plant
A reliable and efficient mobile crushing plant is a sum of several factors working together smoothly, which is well illustrated on Metso Mobile’s latest and most advanced track-mounted jaw crusher plant, the Lokotrack LT120.
ignificantly, the Lokotrack LT120 uses the same field-proven technology seen in Metso’s tracked units for over 26 years. “Building on this track record, the LT120 combines crushing performance and userfriendly design in a new, revolutionary way,” points out Andrew Stones, sales manager for Barloworld Equipment’s Metso Mobile division (Barloworld Equipment is Metso Mobile’s Southern African dealer). “A giant leap, for example, was taken in the bracket and damper design to ensure incredibly smooth operation.” The new on-board C120 jaw crusher, with its feed opening width and depth of 1 200 and 870 mm, respectively, provides excellent capacity even in the toughest applications
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and is optimally designed to meet the requirements of aggregate producers, medium- and large-scale contractors, and mining concerns. Metso’s primary targets in developing this unit are safety, reliability, simplified maintenance, energy efficiency and long operational life. Good examples of in-built safety on the Lokotrack LT120 include sturdy, easy-toopen composite flywheel guards, and hydraulically folding and locking feed hopper sides. Additionally, jaw die bolts are readily accessible. “The result of in-depth field research, the C120 comes equipped with a large feed opening, a very aggressive cavity nip angle and an extremely long stroke in the bottom of the cavity to achieve the highest possible
The Lokotrack LT120 is the latest and most advanced of Metso’s track-mounted jaw crusher plants
capacity in its class. Plus for the first time, the same Lokotrack model is available either as a hydraulically or electrically driven option,” Stones continues. Power delivery on the hydraulic version is provided by a 310 kW Cat C13 engine. In turn, the Lokotrack LT120E electric powered unit sources its energy from an external supply or a 420 kV on-board diesel generator, depending on the preferred configuration setup. The operating weight on the LT120 and LT120E are 57 and 63 t respectively, with the same compact dimensions for road legal lowbed transportation.
ELECTRA Special Stand G23, Hall 6
VERDER | PERFECT TIMING
Pumping out new pumps Industrial pump supplier Verder Pumps will be celebrating one decade of success in the South African market by launching two new pumps at the 2012 Electra Mining exhibition.
erder Pumps marketing manager, Laetitia Möller, points out that the company will be officially launching a new range of Verderhus screw channel pumps and Verderflex Dura 45 peristaltic hose pumps. The company will also be exhibiting tried-and-trusted models such as the Verdermag magnetic drive centrifugal pumps and Verderair air-operated double Diaphragm pumps. “Verder South Africa was established in 2002 with just four employees. Today, the local division has distinguished itself as one of the fastest-growing companies within the Verder Group over the past decade. We have found it fitting to celebrate our 10th year in the country by launching new products at Electra Mining as the mining industry is our largest market, and the event serves as the ideal platform to engage with some of the largest and emerging names in the industry,” she explains. Verder sales engineer, Hannes Liebenberg, highlights the fact that the new Verderhus range is ideally suited to the gold and platinum mining sectors. “The local gold and platinum mining industries have major problems in dewatering shafts and sumps where there is a high content of solids and abrasive products with a low water pH level. The Verderhus pump is perfect for removing this slurry, due to the fact that it is specifically designed for discharging highly abrasive, corrosive and high-flow materials.” According to Liebenberg, the Verderhus pump has a corkscrew shaped impeller and a cone-shaped 45-degree housing. “The corkscrew and cone-shaped casing make this pump completely different to any other pump in the local market. This design ensures that the material that comes into suction inlet of the pump does not hit the impeller at a 90-degree angle but rather at a 45-degree angle. Once the material hits the impeller, it is pushed along the 45-degree angle of
TOP Model B Close coupled Verderhu ABOVE Model L Long coupled Verderhus BELOW bottom left: A Dura 45 BELOW RIGHT Model T Submersible verderhus
the cone to the back of the casing, where the centrifugal force provides displacement. This design ensures that the material is typically expelled within two revolutions of the impeller, which eliminates the risk of blockage and associated downtime.” Liebenberg adds that the Verderhus model is able to pump solids that are up to 80% of the discharge diameter, which ensures a smoother and more efficient flow. “The pump is also small and easy to install.” Verder Pumps will also be launching the Verderflex Dura 45 peristaltic hose pump at Electra, adds Möller. “The new Verderflex Dura 45 peristaltic hose pump is the latest in the class leading Verderflex Dura family of industrial peristaltic pumps. The pump gives a 33% improvement in continuous flow when compared to other pumps in its class, which lowers its overall running cost. Additional features of the Dura 45 range include a 16-bar pressure rating, shimmable rotor shoes for precise control of discharge pressure and optimum hose life, a ringfeeder slip bush to protect against a stalled rotor, fully supported rotor shoes and a simple flange assembly to reduce hose change downtime.”
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ELECTRA Special Stand C18, Hall 6
BECKER | SOLID ON SAFETY
Across a broad spectrum Becker Mining South Africa will be showcasing a range of EMIS electrical flameproof equipment at this year’s Electra Mining exhibition.
ecker specialises in the design, manufacture and supply of energy distribution, automation, communication, transportation and roof support systems meant to enhance safety in underground mining infrastructure systems. It will also be launching a new EMIS ProLoc electronic protection and control relay system for optimum protection of motor and feeder circuits connected to outlet sockets. This system is suitable for thermal overload protection of conveyors, compressors, crushers, fan and pump motors, as well as shuttle cars and flitting panels. These compact switchgear units, with power ratings up to 4 000 kVA, are available with primary nominal voltages up to 11 kV and secondary nominal voltages up to 3.3 kV. Becker’s modular systems range from a simple single technology system to an integrated multi-technological system, and encompass all aspects of the most advanced mining communications and technology. These systems include leaky feeder communications systems, tagging and tracking systems, belt rip detection systems, environmental monitoring equipment, underground WLAN applications, and terrestrial radio and data equipment. Its latest patented tri-technology Collision Avoidance System (CAS), which has been developed to overcome the limitations of existing systems, will also be showcased at Electra. The CAS system provides levels of audible and
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Becker Mining South Africa’s manufacturing arm of communication systems and controls manufactures belt protection systems that automatically detect tears or rips in conveyor belts
visual warning proportional to the position of the threat and also has the ability to stop a vehicle, should this be necessary. The company has also strengthened its position in the design and supply of hoist rope attachment systems by acquiring the exclusive rights for Pfeifer Drako steel wire hoist rope. Its range includes safety detaching hooks, mine winding components, friction winder attachments, cappels, clamps, compensating gear, mine winder brake components and guide rope attachments. Becker steel arch haulage and tunnel permanent supports systems are designed for use in friable ground in haulages, incline shaft portals and special shafts. Alert Pumpmor’s range of slurry, submersible, horizontal and vertical pumps efficiently copes with medium-, heavy- and severe-duty slurry pumping, as well as large and fibrous solids transfer. These pumps are also suitable for high-pressure slurry and dirty water transfer, as well as soft pumping applications and shear sensitive slurries. Also on display will be Kito lifting equipment, which consists of Kito lever, chain and electric chain blocks; and high-speed, low air consumption air hoists.
ELECTRA Special Stand J5, Hall 6
MELCO | WHAT A SIGHT
The world’s largest motorised pulley on show Conveyor equipment manufacturer Melco will be exhibiting the world’s largest motorised pulley at the Electra Mining exhibition. The 250 kW Rulmeca motorised pulley, which weighs 4 980 kg, is ideally suited as a belt conveyor drive solution for large volumes of bulk material for mining applications.
his particular model of motorised pulley is 1 000 mm in diameter with a 1 800 mm face length. It has a belt speed of 4 m/s, 3 000 Nm of torque and a belt pull of 58 800 Nm, making it the fastest and most powerful motorised pulley in the international market, and is capable of improving productivity and efficiency in African mining projects,” notes Melco product manager, Bryan Krynauw. According to Krynauw, motorised pulleys are the next step of advancement in the African mining sector. He points out that the Rulmeca range of motorised pulleys come in power ranges varying from less than 1 kW to 250 kW, with pulley diameters ranging between 220 and 1 000 mm. “Only the shell of the motorised pulley moves when installed, which makes it an extremely safe design for any application. The compact design of the motorised pulley also makes it more costeffective and easier to install, compared to standard pulleys,” he continues. Krynauw points out that the Rulmeca motorised pulley is considered one of the most reliable, effective and safe conveyor drive systems in the world, thanks to its design,
Different angle views of the Rulmeca motorised pulley
which encloses the drive and gearbox inside the drive pulley. “By enclosing all drive components within the pulley shell, the unit becomes considerably more compact and efficient. An added safety feature of the Rulmeca motorised pulley is the fact that all electromechanical components are sealed to IP67 standards within the steel pulley shell, thereby increasing reliability and operator safety, while minimising drive size and reducing noise.” Melco MD Gavin Hall highlights the fact that the company will once again be exhibiting its internationally recognised range of
rollers, idlers and frames, which have proven to be tried and trusted in the industry for more than 40 years. “Melco has been exhibiting at Electra Mining for a number of years, and we view the event as an important medium to strengthen our relationship with new and existing clients by meeting with them face-to-face on our stand. What’s more, Electra Mining attracts professionals from across the globe and serves as an important method of keeping clients up-to-date with the latest trends and innovations in mining,” he says.
SECURING GLOBAL TERRITORY
An African growth strategy Africa, to a large extent, is the last truly untapped minerals rich continent. While the majority of the South African mining industry are not taking advantage of this fact, minerals processing equipment supplier Roymec Technologies is, writes Laura Cornish.
ince its establishment over 10 years ago, Roymec Technologies has achieved significant success on the African continent, having supplied equipment and services to 13 different African countries. “While there are still some opportunities in South Africa, the real growth opportunities lie across our borders. We believe, however, that the key to achieving true success in Africa is to align ourselves with the most active mining players on the continent – who are primarily based in Canada, Australia and Asia,” says Hoosen Essack, Roymec Technologies’ sales director. In line with its African objectives, Roymec has already established a local presence in Roymec Technologies is recognised for its thickener designs
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South East Asia, and will look to achieve similar set ups in Canada and Australia. In South East Asia, Roymec has established a partnership with engineering company PWA Technology, a Malaysia-based engineering and trading company. In addition to assisting the company attain new business in this zone, including Malaysia,
American company Tecpromin. Both businesses are now aligned and working together to attain significant business on another of the world’s minerals-rich continents. Tecpromin, with offices in Chile, Peru and Argentina, is focused largely on the supply of minerals processing equipment. “With the use of Roymec’s designs,
The key to achieving true success in Africa is to align ourselves with the most active mining players on the continent Indonesia and the Philippines, Roymec will look to use its local presence to springboard into Australia. “The time zone is the same, and the two regions are only separated by a six-hour flight,” Essack notes. To further its global growth efforts, Roymec has also partnered with South
manufactured through local fabrication facilities, the equipment is tailored for the South American mining markets,” Essack states. “Regardless of the final option we choose, there is a priority for finalisation of a business concept over the next 12 to 24 months
for both Australia and Canada,” says Essack. Roymec’s strategy to align itself with relevant international mining players has a two-pronged benefit. “There is another mining trend emerging with speed,” Essack points out. He continues: “Global mining houses with projects situated across multiple continents are strategically aligning themselves with service and supply companies that have local establishments across various continents. Mining companies are showing a definite preference for choosing to work with and establish relationships with suppliers that can deliver a standard quality and service level regardless of location. We want to be such a partner for companies across the globe”.
Achieving remarkable success on a new product Earlier this year, Roymec launched a new thickener feedwell technology into the market. Having employed the services of a Wits University postgraduate, not directly involved in the mining industry, Essack believes Dr Alexei Krassnokutski was able to offer an entirely new and fresh approach to thickeners and feedwell design and efficiency inhibitors. “After numerous test phases, we ultimately designed the Radflow feedwell, (entirely different to any feedwell currently available on the market) which counters all of the adverse effects encountered on operating units, thereby ensuring that flocculated feed is symmetrically introduced into the
The Kroomdraai facility with an insert of the model showing the newly developed feedwell
thickener body.” [See the April 2012 issue for additional information.] In the space of just a few months, the company is already supplying two of its new thickeners to the first gold plant in Azerbaijan, a further three to the Kromdraai water treatment plant in eMalahleni and another unit destined for Kazakhstan. “We predict that this novel new South African thickener design concept will revolutionise the global thickener market,” says Essack. A close-up view of the Roymec Technologies thickener feedwell
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The processing key for low While the uranium market continues to look positive, an increasing number of lower grade uranium ore deposits are being exploited. Price however remains a major driving factor for production, says AMEC principal process engineer, Alan Drake.
aking into account the nuclear energy demands across the globe, the next few years will be a period of high activity for uranium and the nuclear power market, and while uranium prices are set to increase, so too are the number of lower grade ore deposits being targeted. The nuclear industry experienced a turbulent period last year as uncertainty hung over its future following the March 2011 Fukushima nuclear station accident, in Japan. However, in light of this, the World Nuclear Association states that electricity demand is increasing twice as fast as overall energy usage, and according to Drake, growth in global energy demand will continue rising. “While the global offices of engineering and project delivery firm AMEC continue to work on a range of commodity projects throughout the world, there is significant opportunity for AMEC to further strengthen its footprint in Africa’s uranium market. However, the price of uranium remains a key determinant in the supply and demand fundamentals of the commodity,” Drake continues. To fully capitalise on the uranium market,
The Langer Heinrich uranium plant at night
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the uranium price would need to remain sustainable for the immediate and long-term future, coupled with a strong appetite for developing uranium production. “Ultimately the price of uranium will determine the extent to which uranium mines are developed. If we look at where uranium demand is currently, and where it is anticipated to be in the coming years – taking into account the number of nuclear power plants that are currently being built and planned in the coming years – the exploration of lower
between the United States and Russia, which is worth approximately 25 million pounds of uranium per year, set to expire in 2013. This will result in a uranium shortfall of 25 million pounds, which makes up for approximately 40% of United States’ requirement, thus indicating how the market could start to turn in the next few years.
Processing Innovation Drake says that because of the lower grade of the ore being mined, innovation in treat-
To fully capitalise on the uranium market, the uranium price would need to remain sustainable for the immediate and long-term future grade ore deposits is a definite option to explore,” he points out. Some of the current large supplies of uranium are also not going to be around to feed this demand in the coming years – another factor affecting the commodity’s demand. Drake cites an example of the Highly Enriched Uranium down blending agreement
ment and processing of the ore needs to be considered. Over the past two decades, there has not been a driving need to change the way uranium is processed, largely due to the slowdown in demand over that period. There needs to be a different, if not better way of processing low grade deposits. “There is no
grade uranium disputing that the standard processes work, but they haven’t been challenged to become more cost-effective. This opens up a number of avenues for companies to study the processing trends of uranium in order to yield large cost saving benefits, as well as to accommodate these lower grade ore bodies,” Drake points out. While considering alternative process routes for a recent uranium project, Drake says that AMEC metallurgists looked at how nano-filtration and membrane technology can be employed. About 22 years ago membrane technology was an expensive, unexplored and untested option. Today, however, membrane technology has become more cost effective by comparison with solvent extraction and, although not yet a fully mature technology, it is now more commonly accepted. Drake notes that AMEC has gone as far as initiating pilot plant test work using the technology, demonstrating that it is possible to replace solvent extraction with membrane technology. AMEC is well positioned to take advantage of the current high activity with proven capabilities in the development of uranium resources. The company has been involved in eight uranium projects located in various regions across Africa, and is currently undertaking two uranium studies for projects in Namibia. TOP The World Nuclear Association states that electricity demand is increasing twice as fast as overall energy usage ABOVE With the market for uranium looking positive, an increasing number of lower grade uranium ore deposits are being exploited
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Drilling and Exploration
A saving grace
Exploration drilling forms an integral part of the mining value chain and is essential when validating and understanding the geology of potential new projects. Why then is the drill operatorâ€™s safety such a neglected area, asks Laura Cornish.
he local mining industry has become largely progressive over recent years and is devoting significant time and money on improved environmental practices, uplifting and supporting surrounding communities and, most importantly, on enhancing health and safety. â€œWhile working safely has become a key priority for the mining houses, drilling is one area where safety has been overlooked, often resulting in unnecessary accidents and serious injuries,â€? says Colin Rice, founder of Dicasa (the Drilling Industry Certification Authority of South Africa). Problems that have been identified include not understanding the dynamics of the drilling apparatus, how to use it and implement it properly, and respecting the machine.
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WHO IS DICASA?
ecause no recognised driller certification and training programmes exist in the industry, Dicasa’s intention is to develop a certification framework for all drill operators, through to supervisory level. The intention is that this will ultimately become recognised and accepted as compulsory for drill operators across the entire mining industry. At present, all driller training in South Africa is done on an individual company basis. Many of the larger contracting companies have training facilities where their staff are trained on practical aspects of exploration and production drilling. In most cases, these facilities are used exclusively for in-house training. No independent drilling industry training facility exists and, as a consequence, no industry accepted competency standards exist. In an effort to address this situation, the National Diploma: Drilling Practice was designed and implemented in 1989 by the South African Drilling Association. Rice chaired the committee responsible for the design of the programme, the generation of course material and its implementation at what was then Technikon SA. The diploma was aimed specifically at qualifying supervisors and junior managers in the industry and to attract new entrants to the industry. For a number of reasons, interest in the qualification declined and it is no longer offered. Dicasa was formed to carry out the work Rice started implementing decades ago.
“This, however, is changing. In the past five years, mining and exploration houses have put increasing pressure on contracting companies to provide ‘proof ’ that their staff are correctly
and adequately trained to operate drilling equipment.” And Rice, through the Dicasa foundation, has every intention
GEOSERVE is a BBBEE company owned by Royal Bafokeng Holdings (Pty)Ltd.
The objectives of Dicasa are far wider than merely certifying that staff are competent to operate equipment
GEOSERVE is a specialised exploration drilling company that offers drilling services for the purposes of qualifying the required resources. Focusing on all resources including gas, coal, gold, platinum and diamonds drilling.
of fulfilling this industry requirement. “The objectives of Dicasa are far wider than merely certifying that staff are competent to operate equipment. We believe that the upliftment of the industry is critical to our survival and development, and this is dependent upon making the industry an attractive one to be employed in. The driller and assistant drillers are a backbone of the industry and many have worked in the industry for many, many years, yet they have no recognition whatsoever, no defined career path and very little opportunity to move between specialisations. It is Dicasa’s primary
The company prides itself on obtaining the ISO 9001:2008, ISO 14001:2004 and OHSAS 18001:2007 standard certifications.
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CERTIFICATION The certification framework has identified 10 distinct drilling specialisations: • diamond core drilling – surface, medium – hydraulic swivelhead • diamond core drilling – surface, medium – longstroke • diamond core drilling – surface, deep • diamond core drilling – underground, electro hydraulic • diamond core drilling – underground, pneumatic • geotechnical investigations • rotary drilling – blasthole • percussion drilling – blasthole • rotary percussion and dual tube reverse circulation drilling • raisebore drilling. objective to address this unacceptable situation.” Is Dicasa making progress and reaching its objectives? Rice has been working on developing a drilling certification framework through Dicasa since early 2010. “Interestingly, the mining houses have been more proactive in this area and have become the driving force, as opposed to the drilling contractors,” Rice continues. In June last year, Dicasa held a meeting with 14 different mining companies which indicated that a drilling standard is absolutely necessary to improve safety and standardise operational procedures. “Kumba Iron Ore has been particularly responsive, and we now have a well-researched and refined document that I hope to have certified with the Mining Qualifications Authority, which has listed drilling practices as a scarce skills area.” Rice notes. De Beers and Lonmin are even looking at incorporating the standards document into their tender forms. For now, Dicasa holds about four or five training courses every year, with about 30 people attending each course.
Drilling and Exploration
A NEW IRON PLAYER...
...on the Bushveld Complex A new exploration and development iron ore mining player has emerged on the Northern Limb of the Bushveld Complex, having successfully listed on London’s AIM stock exchange.
n 16 August, newly formed Ironveld raised £3 million (R39.12 million) at £6.75 a share, following the successful initial public offering on London’s alternative stock market and a reverse takeover of another London entity, the Mercury Recycling Group. The cash will be used to fund the exploration and development of iron ore projects within the mineral-rich Bushveld Complex. The company has interests in prospecting rights in the Northern Limb
“We intend to mine a magnetite resource of about 2.4 Mtpa, which in turn will supply feedstock for its plant, expected to produce 1 Mtpa of pig iron” specifically, with rights that cover a group of seven adjacent farms, measuring an area of 165 km2. According to the company, the intention is to mine titanium-magnetite iron ore present across its properties as feedstock for its own pig iron plant. “We intend to mine a magnetite resource of about 2.4 Mtpa, which in turn will supply feedstock for its plant, expected to produce 1 Mtpa of pig iron. There is also potential for vanadium and titanium by-products,” says CEO Peter Cox.
Drilling is essential during the exploration process
Inside Mining 09/2012
Drilling and Exploration
DIAGRAM 1 Map showing the different Limbs of the Bushveld Complex
With 28 km of outcropping magnetite ore, and 12.8 km drilled to date, the company has a current resource of 11.46 Mt of iron from 6.8 km of strike. The total ore resource target is 40 Mt of iron. With good infrastructure of roads and rail, and access to power and water, as well
as a completed scoping exercise, the continuation of exploration and the preparation of a feasibility study is warranted. The Ironveld board will see that the project is developed rapidly with the intention to commence production in 2015, subject to receipt of the appropriate mining rights
and securing the necessary funding. Because the company is venturing into long-term project work in the area, it will consider other iron ore opportunities in the vicinity of its core project, when and if they become available. “We are delighted with the support shown by both existing and new shareholders for the launch of Ironveld. The management team has long-standing experience of the high-quality assets within the group and significant work has already been carried out with the drilling programme well advanced. I believe the board has the right blend of operational and capital markets experience with an exceptional track record of delivering significant returns for shareholders. Ironveld is well positioned to take advantage of further opportunities within the region and beyond,” says chairman Giles Clarke. The company announced last week that it is facing a legal challenge from a tribe claiming it has rights to the land in the Bushveld Complex, adding that it has taken advice and believes there are no grounds for a case.
Driving customer service through skills development
The Atlas Copco ACademy is responsible for the in-house skills development of all employees. Through its Apprenticeship and Training in Africa programme, the ACademy provides employees with the knowledge that empowers and inspires them to deliver excellent customer service. www.atlascopco.co.za
Visit our stand Hall 6, Stand G21
Visit our stand D4 in the Outside Triangle at Electra Mining
Drilling and Exploration
WEST AFRICAN ATTRACTION
Fourth mine in the making
TSX/ASX-listed Endeavour Mining Corporation has received the official decree from the government of the Ivory Coast granting its Ivorian subsidiary a mining permit for its 85%-owned Agbaou gold project, which is under construction and on track to begin production in the first quarter of 2014.
TOP View of Endeavour Miningâ€™s Youga process plant BELOW Mining at Endeavourâ€™s Nzema project
Inside Mining 09/2012
he terms of the mining permit are as expected and include a royalty of 3% to the state, a 10% free-carried interest to the state and an area of 334 km2. It was previously agreed that on receiving the mining permit, Endeavour will grant a 5% free carried interest to SODEMI, the State Company for Mining Development of Côte d’Ivoire, bringing the state partner’s total interest to 15%. There are no other permits required for construction and production at the Agbaou gold project. The recruitment of key project personnel is 100% complete, and the crop compensation of key infrastructure zones has entered the advanced stage. This is in line with expected timelines to reach production in 2014’s first quarter. Once operating, Agbaou will deliver an additional 100 000 ozpa. Endeavour has a strong financial base from which to invest in long-term operational growth, exploration to replace and increase reserves, and funding for acquisitions. In August 2012, Endeavour announced a definitive agreement to acquire TSX-listed Avion Gold to become one of the largest West African gold mining companies with four producing mines and an attractive pipeline of exploration and resource development prop-
Endeavour has a strong financial base from which to invest in long-term operational growth
INTRINSICALLY SAFE SOLUTIONS
erties. The Avion transaction is expected to close in October 2012. The acquisition will immediately increase Endeavour’s forecast gold production by approximately 50% to between 282 000 and 304 000 oz for 2012. “The acquisition of Avion complements our strategy of becoming a leading and diversified West African gold producer. Avion’s Tabakoto mine and Kofi property in western Mali and the advanced Houndé property in Burkina Faso fit very well into Endeavour’s production and development portfolios. At closing, Endeavour’s gold production immediately rises to approximately 300 000 ozpa including the Tabakoto mill expansion and completion of Agbaou construction, and our gold production is forecast to reach approximately 450 000 ozpa. Endeavour has a well-established track record of using its financial and operating strengths to create value and produce results,” says Neil Woodyer, CEO of Endeavour.
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Drilling and Exploration
LOOKING FOR URANIUM...
...finding coal instead ASX-listed uranium explorer A-Cap Resources’ Botswana-based exploration team has discovered two new coal projects in Botswana, while continuing its exploration programme for uranium in the basal stratigraphy of the Karoo Supergroup.
he first discovery occurred at the Mea prospect while drill testing surficial radiometric targets. A vast new coal field has possibly been discovered. This area will now be identified as the Mea coal project. Initial analysis of selected seams has returned raw coal qualities that compare
favourably to known higher quality coal deposits in Botswana and abroad. The second discovery, Bolau, has been made on two separate licence areas and is interpreted to be an extension of the African Energy’s Sese coal discovery. The coal logged occurs in two separate seams that vary between 3 and 25 m in
thickness. At this stage no samples have been assayed to determine coal quality. In accordance with Botswana law, A-Cap notified the minister of Minerals, Energy and Water Resources of these discoveries. At the same time, A-Cap applied for an amendment of the conditions of its existing licences to include coal, as it only held licences for uranium.
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Pre-registration is now open for Electra Mining Africa, the ultimate market place for all stakeholders involved in the mining, construction, industrial and power generation industries. Visitors can expect to see leading local and international industry players in the packed halls and outside precincts. Itâ€™s the ideal place to view the latest in technology and equipment, innovative products and new supplies and services. Tr a n s p o r t f o r t h e M i n i n g I n d u s t r y
Experts will be on hand to give advice, live demonstrations will be happening daily and co-located conferences and workshops will add even greater value. Electra Mining Africa is recognized as the second largest mining show in the world and the biggest trade exhibition in southern Africa with global recognition for its broad reach across mining, construction, industrial and power generation industries. Electra Mining Africa and co-located Elenex Africa, Machine Tools Africa and Transport Expo runs from 10-14 September 2012 at the Expo Centre, Nasrec, Johannesburg, South Africa.
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Drilling and Exploration
AK6’s Karowe transpires TSX/NASDAQ-listed Lucara Diamond’s new Karowe mine is ramping up with speed and making excellent progress.
arowe mine is developed from the company’s AK6 diamond project. It is 100%-owned by Boteti, in which Lucara has a 100% indirect interest. Karowe is located in north-central Botswana and is part of the Orapa/Letlhakane kimberlite district, one of the world’s most prolific diamond producing areas. The Kimberlite at the Karowe mine comprises a single, trilobate Kimberlite pipe, which is ‘pinched’ at surface and its sub-outcrop consists of a core of Kimberlite, covering an area of 4.2 ha that expands to a 7 ha at a 120 m depth, surrounded by an area where
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Drilling and Exploration
forward. The milestones achieved in the past four months far exceed most other new mine ramp up profiles. All involved in achieving this should be commended. In
feel have not achieved an acceptable market price. Like many other diamond companies, we anticipate an improvement in the diamond market in the latter part of the year.
Karowe has an indicated resource of 51 Mt containing an estimated 8.2 Mt of diamonds these challenging market conditions, Lucara is fortunate to be in a strong financial position, having not drawn down from its US$25 million revolving credit facility. This gives us the option to retain goods that we
The viewing of the diamonds in Antwerp will allow Lucara to take advantage of this expected strengthening of rough diamond pricing,” says William Lamb, Lucara president and CEO.
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the Kimberlite is capped by basalt or basalt breccia. Drilling has shown that the Kimberlite bulges to a maximum area of 7 ha at a depth of 120 m. Today, the new mine’s production rampup is making excellent progress. To date, more than 310 000 t have been processed, yielding in excess of 87 000 carats. Final capital expenditure for the development of the Karowe mine is also complete and has come in below the original approved budget of US$120 million (R1.01 billion). The mine site has fully transitioned to operations personnel and the excellent safety standards developed during construction have been maintained. Lucara was first granted a mining licence in 2008 over the AK6 diamond project. It consists of three lobes: South, Center and North, of which the South Lobe makes up approximately 75% of the kimberlites’ resource potential. In July 2010, a formal decision was made to proceed with the construction of the AK6 diamond mine. Karowe has an indicated resource of 51 Mt containing an estimated 8.2 Mt of diamonds. The mine design delineates a probable reserve of 36.2 Mt of ore, containing an estimated 6.3 million carats of diamonds at a 1.5 mm bottom cut-off size, in an openpit to a depth of 324 m. The reserves will be mined over an estimated 15-year life. The process plant has been designed at throughput rate of 2.5 Mtpa. The Karowe mine transitioned from construction to commissioning in the second quarter of 2012, with its first diamond being recovered on 4 April. During the month of April, production commissioning activities commenced and 30 000 t of kimberlite was treated yielding 10 200 carats. Commissioning and testing continued through May and June with 19 062 carats and 35 007 carats being recovered respectively. Commercial production commenced on 1 July. The forecast for the second half of 2012 anticipates the treatment of 1.02 Mt and the yield of 208 010 carats. Total production for 2012 is expected to be approximately 270 000 carats. Lucara is forecasting to achieve design capacity during the first quarter of 2013. “The team on site at Karowe is doing an excellent job of moving Karowe production
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Drilling and Exploration
Uncovering magic prospects
Drilling at Miyabi
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Recent drilling results from AIM/Alt-X-listed African Eagle Resources’ joint venture partner, BrightStar Resources, have indicated a strong potential to increase the current 520 000 oz gold resource on the Miyabi gold project in Tanzania.
he potential for additional resources comes from the newly discovered zones of gold mineralisation at the Chui prospect and at Dalafuma, both of which are located to the south of the known gold resources. “These are extremely encouraging results and support our belief that Miyabi has much more to reveal,” says BrightStar’s MD, Mike McKevitt. Miyabi is located in the Lake Victoria goldfields in Tanzania. The property has mineral resources contained in several deposits totalling 12.4 Mt at 1.3 g/t gold. This resource comprises 520 000 oz of gold (at a 0.5 g/t cut-off), estimated in accordance with JORC. The resource comprises 370 000 oz of indicated mineral resource and 150 000 oz of inferred mineral resource. BrightStar has a joint venture with African Eagle Resources, where it may earn a 75% interest in the project by sole funding exploration to completion of a bankable feasibility study. Six of the seven individual gold resources estimated to date occur in an en echelon pattern of shear zones that cut across the north-west corner of the Miyabi greenstone belt. This major structural corridor is named the Miyabi Structural Corridor (MSC) and trends north-east to south-west, extending for a length of 7.7 km through the Miyabi property and is some 800 to 1 000 m wide. Large areas of the prospective MSC remain to be effectively drilled and this has been the prime focus of BrightStar’s exploration programme in 2012. Between May and July 2012, a total of 54 RC holes for 4 971 m and 52 aircore holes for 2 138 m were drilled. The drilling programme achieved two notable successes: • A new 900 m long zone of gold mineralisation was discovered approximately 1 km along strike from Dalafuma – the Chui prospect. One significant high-grade intersection has already been obtained. • A 300 m long mineralised zone with several significant highgrade gold intersections was confirmed on Dalafuma.
South Africa’s only event for Mine Managers 7 - 9 November 2012, Riverside Sun Resort, Vanderbijlpark, South Africa The Mine Managers Show is the only event in South Africa aimed speciﬁcally at Mine Managers on the country’s largest and most prominent mining projects. It is case study-driven, interactive and practical. The content has been engineered by Mine Managers for their peers and colleagues and offers a unique platform for mine managers to discuss their challenges and opportunities amongst their peers. In content, scope and experience The Mine Managers Show is the only event of its kind in South Africa.
Expert speakers include:
Mark Roebert KDC Senior Manager Operations – Projects Goldﬁelds, South Africa
Francois Janse Van Rensburg VP: Technology AngloGold Ashanti, South Africa
Emil De Villiers Senior Process Engineer Kumba Iron Ore, South Africa
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Investors still confused BY WILLEM SMUTS
Botswana powers ahead as the ‘Home of the Diamond’ with De Beers’ announcement that it will now be sorting its rough stones in Gaborone and an international diamond company and local retailer launches the unique Swana Diamond in Botswana. Swana diamonds originate from, and are cut and polished in Botswana by a select group of experts. Every Swana diamond is laser-etched with
the Swana logo and its certificate number. An international certificate, bearing the Botswana Stamp (a mark of quality signifying both high-quality workmanship and high ethical values) therefore accompanies every Swana diamond. The brand is a unique and special cut of diamond, featuring 89 facets, rather than the conventional 57, for greater brilliance and internal fire. Further afield, the Eritrean government, through the Eritrean National Mining Corporation (Enamco), has announced that Enamco intends to acquire a 30% paid participating interest in Sunridge Gold’s Asmara Project in Eritrea. This 30% interest is in addition to Enamco’s existing right to receive a 10% non-assessable interest that will be carried to production by the participating partners. Earlier it was also announced that NGEx Resources has entered into an agreement with Bisha Mining Share Company to sell its Mogoraib Exploration License, which covers the Hambok copper-zinc deposit. Bisha Mining Share Company, which is 60% owned by Nevsun Resources and 40% owned by Enamco, operates the Bisha gold-copper mine located nearly 16 km from the Hambok deposit.
“Most proposals in the State Intervention in the Mining Sector (SIMS) report commissioned by the African National Congress (ANC) in 2010 were unlikely to be implemented because of the importance of a growing industry,” Michael Spicer, vice president, Business Unity SA.
at a recent conference that the SIMS document had made some positive proposals, but the fundamental flaw in the report was that the overall intention of the authors was not to focus policy on growing the mining industry, but ‘a static redistribution approach’ based upon the assumption that the industry would continue to operate ‘on autopilot’ regardless of the nature of state intervention. He said the authors assumed that with the planned interventions, investment and production would continue ‘magically’, with the industry unhindered. Among the recommendations in the SIMS report was a 50% resource rent tax on ‘super profits’, increased regulation and ring-fencing of certain minerals, which would prove damaging and drive off investment. This came as critics pointed out that the ANC policy conference again left investors confused about which policy direction the party intended to
INDEX TO ADVERTISERS Atlas Copco
Things getting out of hand? In Zimbabwe, wrangling over mines and mining rights between bankers and local businessmen are starting to sound like the Wild West of yore with people getting shot in wild street gunfights and one killed recently in Kadoma. In Zambia, rampaging coal miners killed a Chinese mine manager and
closer to home folks now refer to the ‘Lonmin mine massacre’ after police killed 34 striking miners. Now I will not discuss whether the police acted rightly or wrongly – for there is a full inquiry under way. What I will say is that I find it scary that people generally think they can do anything and get away with it; suddenly it’s OK to burn and pillage and kill others, and then we are all shocked and hurt when the peacekeepers finally step in – albeit perhaps way too late and crudely?
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take in the future, while President Zuma says: “The party will definitely discuss the issue at its National Conference in Mangaung later this year.” Eish! The Chamber of Mines meanwhile has come out strongly criticising the ANC’s proposed 50% super tax as insupportable, saying in a statement: “What is important for South Africans is how will the state intervention in the mining sector increase the role that benefits ordinary South Africans on the street – how will it increase employment and job creation as we’ve already seen lots of the state enterprises operating inefficiently.”
Inside Mining 09/2012
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