Inside Mining January 2016

www.miningne.ws

af r ic an u pdates on th e

g ro un d a n d un d e rg ro un d

DRA

in the

spotlight Dr Declan Vogt

Making the impossible possible

On the challenges of mechanisation

Beatrix Mine

DRD Gold

Afro Energy

Innovative underground storage

Excellent results from FFG

Unique onshore gas set to soar

ISSN 1999-8872 • R50.00 (incl. VAT) • Vol. 11 • No. 01 • January 2016

cover story

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2

Ins i de Mi n i n g 0 1 | 2 0 1 6

contents

a fric a n up dates on the

gro u n d a n d u n d ergro u n d

17

Monitoring equipment Hazardous-environment sensors can mean the difference between life and death. There are various sensors for different applications.

Read more on page 40

12 Editor’s Comment

Mining & Contracting

5 New beginnings, new hopes

27 More than saving costs

Cover Story

IT & Communication

6 Impossible? Not for DRA

31 Big data in mining

Africa Round-up

34 Smart miners use smart technology

8 News from around the world

Minerals Processing

Economics

36 The evolution of technology and processes

10 A bullish outlook

Latest Equipment & Technology

Focus on Africa

38 Engineering genius

12 HMC increases for Kwale

40 Sensing what humans can’t

Prestigious Projects

43 Quick and efficient solution

14 Creating storage initiatives

45 Measuring diesel particulate matter

16 Excellent results from FFG

47 Containing a toxic threat

18 Unique onshore gas set to soar

49 Scalebility, availability, reliability

Thought leaders

51 Severe-duty water cannons for mines

20 A bright future beckons

Events

Mechanised Machinery

53 A global drawcard

22 Can mechanisation save SA’s ailing mines?

54 And the winner is…

24 Harmonising man and machine

56 The feminine touch

JANUARY

2016 ON THE COVER p6 www.miningne.ws ws

A F R I C A N U P DATE S O N T H E

G RO U N D A N D U N D E RG RO U N D

DRA

IN THE

SPOTLIGHT Dr Declan Vogt

Making the impossible possible

On the challenges of mechanised machinery

BEATRIX MINE

DRD GOLD

AFRO ENERGY

Creating storage initiatives

Excellent results from FFG

Unique onshore gas set to soar

ISSN 1999-8872 • R50.00 (incl. VAT) • Vol. 09 • No. 01 • January 2016

@mining_news www.facebook.com/pages/ Mining-News

31

The DRA Group has been involved in a number of recent mining projects in Africa that have rigorously tested this engineering company’s ‘can do’ approach to project challenges.

Endorsed by In sid e M in in g 0 1 | 2016

3

editor's comment

Publisher Elizabeth Shorten Associate publisher Nicholas McDiarmid Editor Mientjie Kleinhans Assistant editor Mpinane Senkhane Head of design Beren Bauermeister Designer Ramon Chinian

New beginnings, new hopes

Chief sub-editor Tristan Snijders Sub-editor Morgan Carter Contributors Trevor Scott, Dr Declan Vogt, Tony Stone, Jonathan Moore Client services & production manager Antois-Leigh Botma Production coordinator Jacqueline Modise Marketing & digital manager Philip Rosenberg Financial manager Andrew Lobban Administration Tonya Hebenton Distribution manager Nomsa Masina Distribution coordinator Asha Pursotham Printers United Litho Johannesburg Tel: +27 (0)11 402 0571 ___________________________________ Advertising Sales

Ereka Boettger Tel: +27 (0)11 233 2600 Cell: +27 (0)76 557 0528 ereka@3smedia.co.za ___________________________________ No. 9 3rd Avenue, Rivonia 2191 PO Box 92026, Norwood 2117 Tel: +27 (0)11 233 2600

The start of a new year inevitably brings with it new beginnings, new hopes, and New Year’s resolutions.

Then, there is the excitement of the unknown – not knowing what the new year will bring; however, let’s take a look at what we do know.

E

ARLY IN THE new year, we will see

Another interesting prestigious project under

another great African Mining In-

the spotlight this month is the flotation and

daba take place in Cape Town,

fine-grind processes at DRDGold. Apparent-

which promises to be as eventful as

ly, this is the only project of this size in South

ever – with speakers from around the world,

Africa. Those involved in the project learned

networking sessions and exhibitions with the

a few lessons, including implementing incre-

latest and greatest technology available

mental, rather than wholesale, changes.

in the industry. Talking about technology –

Then, we feature an interesting article by

Fax: +27 (0)11 234 7274/5

one theme that has become a buzz phrase

Dr Declan Vogt on how mechanisation can

www.3smedia.co.za ___________________________________

in just about every industry these days is big

possibly save South African mines. In the

data, and the mining industry is no excep-

article, he looks at possible solutions and

tion. Initially, big data was related to the

the appropriate technology for the mines.

likes of search engines, such as Google, or

He also writes that mechanisation needs a

mobile network service providers, which

mindset change – see the article on page

had huge amounts of data that had to

22. Ending 2015 on a high note was the

be processed. In the meanwhile, more

Bentley Year in Infrastructure Conference,

ISSN 1999-8872 Inside Mining

and more industries have realised how

in London.

Copyright 2016. All rights reserved. ___________________________________ All material in Inside Mining is copyright protected and may not be reproduced either in whole or in part without the prior written permission of the publisher. The views of contributors do not necessarily reflect those of the publishers.

important big data management is, and

Annual subscription:

South Africa: R550.00 (incl vat & postage) African countries: US$80 Foreign: US$100 Email: subs@3smedia.co.za

Bentley representatives and other dele-

more about big data in the mining industry

gates were treated to a gala dinner where

on page 31.

the winners of the Be Inspired Awards were

In this edition, we look at the Kwale Min-

announced. We were also privileged to

eral Sands Project in Kenya. The company

meet numerous industry specialists, see the

mines and processes ilmenite, rutile and

latest in software technology and even

zircon at the first modern, major mining

learned a new term: ‘optioneering’. Read

investment in Kenya. Since the operations

about the event on page 54.

started two years ago, the mine has stead-

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

Finalists from various industries, the media,

how it influences business decisions. Read

But, let me not spoil all the interesting

ily increased its quarterly heavy mineral

content in another jam-packed edition of

concentrate (HMC) production to 210 000

Inside Mining. Enjoy this month’s interesting

tonnes. In the Prestigious Projects section,

and varied read!

we look at the latest project at Sibanye’s Beatrix Mine – the building of siloes between two levels, to create more under-

Mientjie Kleinhans

ground storage facilities to reduce business risk and to store and easily move ore to the lower level and out of the mine, by means

@mining_news www.facebook.com/pages/ Mining-News

of a conveyor belt. We look at how the team at the mine have done it and the

follow the link www.miningne.ws/category/events www.miningne.ws/category/news

challenges faced.

In sid e M in in g 0 1 | 2016

5

cover story

Impossible?

Not for DRA

The DRA Group has been involved in a number of recent mining projects in Africa that have rigorously tested this multinational engineering company’s ‘can-do’ approach to project challenges.

I

t is an approach that has been

transported 43 000 tonnes of steel to the

the challenge. DRA was the right match.

part of the DRA culture since Dow-

site, over a grueling 1 800 km route from

DRA engineered and constructed the

ding, Reynard and Associates was

Mombasa, on roads that took two weeks

7.2 Mtpa plant. The scope included two

started by a handful of hands-on

to traverse. Under these circumstances,

processing plants, two tailings dams, a

electrical engineers in Johannesburg

there was a three-month lead time from

45 MW diesel generation plant, as well as related infrastructure. Then, to address

more than 30 years ago. Their determination to find a solution to any challenge was the foundation of their success in the industry and has become a defining element of DRA’s global brand.

Over the past three decades, DRA has established itself as a global engineering design and project management group that delivers diversified engineering services for all mining, minerals processing, operations and infrastructure projects, as well as the energy, water and agriculture sectors. Part of its success is that

“We built the first minerals processing plant in Liberia in the middle of the Ebola epidemic, with an exceptionally tight budget.”

took on the design and construction of its first hydropower plant, Kibali’s Nzoro 22 MW hydropower plant – which now produces sustainable, clean energy for DRA’s clients at a third of the cost of diesel. In addition, the project deadline was brought forward, but DRA rose to the challenge and first gold was poured in September 2013, a month ahead of schedule. Project manager Christoff Badenhorst remarks: “From logistical challenges in a remote area to safety

DRA has an appetite for challenges, honed during its decades of experience

when equipment was picked up in Jo-

challenges brought about by language

in overcoming the logistical and practi-

hannesburg until it arrived on-site, which

and cultural barriers, DRA once again

cal obstacles of working in Africa.

called for exceptionally efficient forward

proved that, in working in partnership

planning and risk mitigation. For the joint

with our clients, we are able to deliver in

mine owners – Randgold Resources,

seemingly impossible circumstances.”

Into the heart of Africa

6

further power supply problems, DRA

One such example is the Kibali Gold

AngloGold Ashanti and Congolese par-

Mine in the north-east DRC, the largest

astatal Sokimo – it was critical to bring

Taking on Ebola

gold mine in Africa, in one of the most

the right engineering and construction

In late 2014, at New Liberty – Liberia’s

remote locations on the continent. DRA

team on board: one that was equal to

first commercial gold mine – being

Ins i de Mi ni ng 0 1 | 2 0 1 6

cover story Ebola outbreak since the disease first emerged in 1976. A potentially tragic situation loomed. The close proximity of the outbreak to the site increased the risk and it seemed possible that

project. The site remained Ebola-free and Liberia’s first commercial gold mine was delivered on schedule. Project manager Rob Welsh sums up the exceptional value delivered: “We built the first minerals processing plant in Liberia in the middle of the Ebola epidemic, with an

the project may not

exceptionally tight budget, surmounting

be able to weath-

all manner of challenges, and ended up

er the epidemic

with a successful project that came in

due to difficult

under budget and absolutely on time –

market conditions.

to the great satisfaction of our client.”

DRA director Angus Fynes-Clinton travelled to the site himself to evaluate how DRA could assist

Value for clients DRA strives to always add value for clients by finding appropriate commercial and technical solutions for all projects.

its client, Aureus Mining, to address the crisis. It was critical to find a solution for protecting the workforce from the disease.

DRA established a secure, closed comconstructed just 100 km north-west of

munity, with health protocols that in-

Monrovia, workers from local villages

cluded detailed screening and hygiene

returned from their rest and recovery

practices, supported by on-site health

leave to an additional checkbox on

workers and immediate access to ‘isola-

their safety form: hardhat, high-visibility

tion ambulances’, in accordance with

overalls, safety boots, gloves, protec-

global best practice. No employee or

tive eyewear, temperature check.

partner of DRA was asked to continue

While they were away on leave, West

working in Liberia against their will, but

Africa was hit by the world’s worst

the team was fully committed to the

BELOW LEFT Safety is part of DRA's organisational DNA BELOW RIGHT As a provider of mining engineering services to major mining houses, as well as emerging producers around the world, DRA is on track to become a global frontrunner in the industry

+27 (0)11 202 8600 www.DRAglobal.com

DRA has a well-established and impressive track record of delivering large and complex infrastructure to the mining and other industries

In sid e M in in g 0 1 | 2016

7

Mining news

from around the continent

DEMOCRATIC REPUBLIC OF the CONGO

Ghana's progress on IMF-driven reforms has been slower than expected

Copper production starts at JV mine The Sinohydro Corp and China Rail-

half of that,” Imena said, blaming a fall

way Group Limited companies have

in global mining prices. “It’s killing us.”

pledged to build $3 billion worth of

Rwanda’s mining revenue was $210 mil-

roads, railways and other infrastructure

lion in the 2014/15 financial year. After

in the DRC in return for a 68% stake

tourism, mining – mostly of metallic ore

in Sicomines, the joint venture in the south-east of the country, Africa’s top copper producer. Mines Ministry chief

Progress on structural reforms: IMF review

coltan – is one of Rwanda’s biggest foreign income earners.

Imena spoke at a ceremony to sign

of staff Valery Mukasa said production

Ghana has made progress on struc-

deals with four mining companies to ex-

was launched on 6 November 2015 at

tural reforms under an International

plore six blocks in the western part of the

a ceremony attended by Mines Minister

Monetary Fund programme designed

country. The four companies – Ngororero

Martin Kabwelulu. China’s state-run Exim

to restore fiscal balance to its sagging

Mining, KNM Combines, Daba Sumpplies

Bank is providing most of the financing

economy, though at a “slower pace

and SEAVMC – will invest $38 million in

for the copper mine, which is one of the

than expected in some areas,” the IMF

Rwanda over the next five years as part

largest in the world. While the DRC gov-

said in a review in November. The West

of a deal granting them 15-year mining

ernment hailed the contract as a model

African country’s economy was one of

licences. “If everything goes according

for mining investment, international

the continent’s strongest performers but

to our plans, these companies will add

campaign groups and local activists

it has slowed sharply in the last two years

more than 28% of the current tin and

criticised it for an alleged lack of trans-

after being hit by a fiscal crisis and a

tantalum production,” Imena added.

parency and concerns that it will bur-

fall in commodity prices that have hurt

Tantalum from coltan is used to make

den the DRC with unsustainable debt.

revenues from its gold, cocoa and oil

tantalum capacitors used in electronic

China has signed several such resourc-

exports. Growth is expected at around

products. Benchmark tin on the London

es-for-infrastructure deals with African

4% in the first half of 2016, with inflation

Metal Exchange had fallen more than

governments in the last decade as it

at 17%, said the IMF. The government will

20% in 2015. The four companies will ex-

seeks raw materials to fuel its economy.

present measures in the 2016 budget to

plore six blocks on the Gatumba mining

reduce the fiscal deficit to 5.3% of GDP

concession, one of Rwanda’s oldest

from the 5.8% initially expected.

mining sites.

Progress on the project has been repeatedly delayed. Exim Bank temporarily halted disbursements in 2012 and

“Implementation of the programme

ZAMBIA

workers had to pump 160 million cubic

has, so far, been satisfactory, with all

metres of water from two pits. Sicomines

end-of-August-2015 performance criteria

has also struggled to secure sufficient

met,” the IMF said after a second review

Union opposes Glencore’s planned job cuts

energy to power the mine, leading it

of the $918 million programme that be-

Global mining and commodities trader

to reduce its initial annual production

gan in April. The review must be ratified

Glencore’s Zambia Mopani Copper

target to 125 000 tonnes. The DRC

by the IMF’s board before a further dis-

Mines should surrender its mines to the

produced more than 1 million tonnes

bursement of funds. Ghana’s president,

government if the company pursues a

of copper for the first time in 2014. The

John Mahama, faces a tough contest

plan to lay off workers as it battles weak

chamber of mines says production will

at this year’s election against opposition

prices, a trade union said in November.

fall to 974 000 tonnes in 2015, however,

leader Nana Akufo-Addo and the per-

The Confederation of Trade Unions

due to electricity shortages and the

formance of the economy is likely to be

of Zambia’s president, Joe Kamutum-

September suspension of Glencore’s

a key issue for voters.

wa, said Mopani should explore other

Katanga Mining unit.

Chinese influence has increased in mining operations across the African continent

8

GHANA

Ins i de Mi n i n g 0 1 | 2 0 1 6

RWANDA

Mining revenue to halve this year

cost-cutting options or surrender its mine. The union echoed comments

by President Edgar Lungu, who had warned that he would not allow Glen-

Rwanda expects revenue from the min-

core to lay off workers at Mopani as

ing sector to halve in the 2015/16 fiscal

part of its plan to suspend production

year due to the collapse in commodity

for 18 months at the mine. Glencore’s

prices, a senior official said in November,

Zambia unit plans to lay off more than

as the East African country signed deals

3 800 workers in Africa’s second biggest

with four companies to invest in its min-

copper producer, citing lower metal

ing sector. Rwanda’s Minister of Mining,

prices and rising production costs. “We

Evode Imena, said he had expected

wish to take this opportunity to earnest-

mining revenue of $290 million this fi-

ly appeal to Mopani to adhere to our

nancial year. “We will possibly achieve

advice. Failing that, government should

africa round-up

take over the running of the mines,” Kamutumwa said. Mopani spokesman Cephas Sinyangwe declined to comment, saying the company was still discussing the planned job cuts with unions. Swiss-based Glencore has pledged to cut its net debt to $20 billion by the end of 2016 to regain the trust of investors after its shares tumbled to record lows this year. London copper veered towards six-year lows, with metals markets braced for fresh pressure after a gauge of China’s factory health showed ongoing weakness in the world’s top metals consumer.

ZIMBABWE

Children walk past a shaft at the Mopani Copper Mine (Source: Bloomberg)

New tax for miners amid belt tightening

stock platinum group metals around”,

for its 13 million citizens, government

Zimbabwe-focused miners such as

officials claim, amid an outcry that offi-

Zimbabwean miners are to be taxed a

Aquarius Platinum were likely to focus

cials are pillaging proceeds from state

new levy to fund exploration activities

on cost containment and avoiding

firms involved in diamond mining.

as the government transforms the Min-

losses, he added. “The coming months

erals Marketing Corporation of Zimba-

will remain exceptionally challenging

ister Walter Chidakwa has said that the

bwe (MMCZ) into a state exploration

for both Kroondal and Mimosa. At both

government is spearheading the setting

company. This comes in the wake of

operations, management’s focus will

up of a state exploration company,

declining exploratory work by mining

be to prevent losses. So, cost-cutting

which will be funded by contributions

firms at a time when miners globally

will be the name of the game; hope-

from miners. He also said that this would

are facing market uncertainties. Anglo

fully, retrenchments can be avoided,”

be attained through transformation

American Platinum has already an-

said Williamson.

of the MMCZ.

nounced that it is cutting expenditure

Zimbabwe has vast mineral wealth,

Mines and Mining Development Min-

“What we are saying is that we want

and delaying capital to 2017. Bruce

spanning diamonds, platinum, gold,

to transform the MMCZ into an explora-

Williamson, the Imara Africa Resource

nickel, chrome and coal, among other

tion company. There is no new levy for

Fund manager, said miners were fac-

natural resources. It has attracted other

exploration, but the small fee that com-

ing risks and uncertainties globally,

mining investors such as Impala Plati-

panies were paying to the MMCZ will

although “there is still a fair amount of

num and Caledonia Mining Corpora-

be increased to about 1% so that the

tion. However, the country has failed to

money can be used to fund exploration

transform its mineral riches into wealth

activities.” Mining industry sources say

A Rwandan mining operation

the operating framework in Zimbabwe is prohibitive of further exploration for current mining projects.

They say the government needs to restore certainty in the industry to motivate investors to commit funds and expand operations.

“Expansion of operations is undertaken through exploration but, sadly, right now, there is very little exploration taking place because the environment is uncertain and investors are sticking to current projects,” said an official from the chamber of mines of Zimbabwe.

In sid e M in in g 0 1 | 2016

9

economics

Uranium

A bullish outlook W

HEN LOOKING at it simply, on a worldwide basis, the demand for nuclear energy (which relies on ura-

nium as its key fuel source) is increasing due to a growing demand for energy and pressure to reduce emissions from fossil-fuel-based sources of energy, such as coal-fired power plants.

China Despite its recent economic turmoil, China is the world leader in the development and construction of nuclear reactors. According to China’s new Five Year Plan, the country will commission more than 100 nuclear reactors over the

While spot market prices for uranium have not yet responded in recent months to growing pressure on the demand and supply fundamentals for uranium, the mediumto long-term outlook remains promising.

By Trevor Scott

next decade. Total investment in nuclear

Japan’s reactors has had a strong signalling effect on uranium markets in that this act represents a return of confidence in nuclear power by the world’s third largest consumer of uranium. Any doubts regarding a possible supply overhang that could come from Japan releasing its stockpiled uranium are gradually dissipating.

India India is making significant advancements in its outlook on nuclear energy and has recently declared its intention to build a strategic uranium reserve. India currently has 21 nuclear reactors in operation with 6 under construction; 22

infrastructure will exceed $100 billion,

Fukushima disaster. Japan’s shutdown

more are planned and another 35 have

with approximately seven new reactors

of all 48 of its nuclear reactor fleet

been proposed. Accordingly, India is

constructed annually between now and

following the Fukushima event had a

likely to become one of the world’s

2030. By 2050, China will have construct-

catastrophic effect on global uranium

largest consumers of uranium over the

ed more than 400 new nuclear reactors,

prices, which was compounded by

next 15 to 20 years. India recently con-

with a total investment in nuclear energy

Germany’s decision to decommission

cluded key uranium supply agreements

totalling over $1 trillion.

8 of its 17 nuclear reactors in response

with Canada and is close to concluding

to the Fukushima disaster. Over the

a supply agreement with Australian

subsequent three years, the spot price

suppliers.

Japan

10

over the same period. The restart of

Japan has, very recently, successfully

of uranium fell from a high of $73 per

restarted its second nuclear reactor

pound to a low of $28 per pound – rep-

The coming supply deficit

following the three-year hiatus in the

resenting a loss of over 70%.

While the outlook for medium- to long-

operation of its nuclear fleet that en-

Long-term contract prices dropped

sued subsequent to the March 2011

from $75 per pound to $40 per pound

Ins i de Mi n i n g 0 1 | 2 0 1 6

term demand in uranium is steadily growing, it is the decline in the supply

economics side of uranium that provides sharp contrast. A supply shortfall of approximately 60 million pounds is forecast to take place by mid-2017. In recent months, key uranium suppliers have shut down operations, most notably in Australia where growing social pressure has led to the postponement or cancellation of several notable uranium projects. Low uranium

Realising possibilities...

prices have also fuelled a lack of investment in exploration expenditure and new mine development. Accordingly, uranium consumers will be hard pressed to find new sources of uranium production in the short to medium term, especially as most existing producers are committed to existing longterm supply contracts.

Key events to look out for in uranium markets in the near future: • the continuing growth of the nuclear build programme in China • the renewed commitment to nuclear power in the United States • ongoing geopolitical tensions between Russia and the Ukraine that could affect supply from both countries • adherence by Japan to its reactor restart timetable •further high-cost mine closures.

Given the supply deficit that is expected to arise in the medium to long term, most analysts agree that a significant increase in the price of uranium is likely to take place. The only question that remains is when.

BELOW Uranium particles

...from mine to market.

Resource Evaluation

Table 1 Nuclear reactors throughout the world Country

Mine Planning

Mining & Mine Development

Materials Handling

Environment & Approvals

Transport to Market

Non-Process Infrastructure

Reactors Reactors Reactors Reactors operable under planned proposed construction

USA

99

5

5

17

France

58

1

1

1

Japan

48

3

9

3

Russia

34

9

31

18

South Korea

23

5

8

0

China

22

27

64

123

India

21

6

22

35

Canada

19

0

2

3

UK

16

0

4

7

Ukraine

15

0

2

11

World total

437

70

183

311

Mineral Processing

Tailings & Waste Management

Smelting & Refining

WorleyParsons adds value through our full scope of services from pit to port including studies, mine planning, impact assessments, permitting and approvals, project management, construction management and global procurement.

46

countries

157

www.worleyparsons.com

offices

35,600

people

In sid e M in in g 0 1 | 2016

11

focus on africa: KENYA

HMC increases

for Kwale Base Titanium, the locally incorporated subsidiary of Australian parent Base Resources, started operations at the Kwale Mineral Sands Project, in Kenya, two years ago, and has steadily increased its quarterly heavy mineral concentrate (HMC) production to 210 000 tonnes. By Mientjie Kleinhans In 2010, Base Resources acquired the

slurried with water and pumped to the

assets and property, financed develop-

process plant.

ment of the project and construction works started by the end of 2011. The

Wet concentrator plant

project was commissioned in October

The slurried ore passes through a vi-

2013 and the first minerals shipment

brating screen of +4 mm and is then

was exported in February 2014. “We

deslimed (to remove the fine clay

have been operating successfully since

component) before being moved to

then, focused on ramp up production

a four-stage, wet, gravity spiral circuit

and optimising process efficiencies,”

to produce HMC. The clay slimes are

says Joe Schwarz, the company’s

impounded in a tailings dam, which

general manager of external affairs

is created from the sand tailings. The

and development.

sand is used to build the containing

The resource features a high-grade ore body with high-value mineral assemblage; the expected life of mine is

12

wall to impound the fine clays in the dam.

13 years. The annual expected produc-

Mineral separation plant

tion for the first six years includes aver-

The first stage in the mineral separation

ages of 80 000 tonnes of rutile, 360 000

plant is magnetic separation, which

tonnes of ilmenite and 30 000 tonnes

pulls the ilmenite out of the HMC as a

of zircon. Over the life of mine, the

discreet product. High-tension elec-

company expects to mine and process

trostatic separation then segregates

140 Mt of ore to produce 4.6 Mt of final

the rutile to final product. “Finally,

products, which are to be exported

what is left is dirty zircon product,

Wet concentrator plant facilities

from its dedicated Likoni marine termi-

which contains other unwant-

T

nal in the Port of Mombasa.

ed minerals, before it goes through a number of clean-

HE KWALE PROJECT is located

Mining operations

near the coast in southern Ken-

Currently, Base Titanium is mining the

zircon,” explains Schwarz.

ya, not far from the Tanzanian

central dune, which contains the high-

The mineral separation

border and mines and processes

ing stages to extract clean

est grades, compared to the north and

plant operates at a feed

ilmenite, rutile and zircon at the first

south dunes. “The blocks that we have

rate of 80 tonnes per hour.

modern, major mining investment in

been mining in the last two quarters

Kenya. The deposits were first discov-

are in a high-grade zone averaging

Supporting infrastructure

ered 20 years ago by a Canadian

in excess of 9% heavy minerals. These

For the Kwale Project to be success-

company, Tiomin Resources, which

are very high grades by world stand-

ful, Base Titanium had to construct

had done most of the preliminary work,

ards,” says Schwarz. Base Titanium

supporting infrastructure, which

including the environmental impact as-

makes use of dry mining techniques

included a tailings dam, an

sessment and community resettlement.

using bulldozers and other ancillary

8 km tarred access road,

It also acquired the environmental

mobile equipment. Once foreign

a 132 kV power transmis-

license and the special mining lease.

materials are screened out, the ore is

sion line and substation, a

Ins i de Mi n i n g 0 1 | 2 0 1 6

focus on africa: KENYA water storage dam, boreholes and a

loader loads about 1 000 tonnes of

port, all of which totalled $60 million to

ore per hour into bulk carrier ves-

construct. “The road has been hand-

sels moored alongside the wharf,”

ed over as a public road that can be

says Schwarz.

used by anybody and it has provided an outlet for the local community

Biggest challenge

members to get to town and market

“One of the biggest challenges in Ken-

their produce. The 14 km power line is

ya is to get a mine up and running in

shared by the sugar plantation, which

this environment. Mining is not yet well

links its factory to our substation,” says

understood in Kenya, so it’s been a

Schwarz. The mine also had to provide

steep, lengthy learning process and ob-

water for the project and, therefore,

taining all the necessary authorisations

built a $17 million dam in the nearby

from government and buy-in from the

Typical applications

I lmenite comprises titanium and iron oxides, and is commonly used to produce pigment for the manufacture of paints utile is titanium dioxide; some is also R used in pigment production, but also for titanium metal ircon is a zirconium silicate compound Z and is used largely in glazing and tiling applications

communities. It has been a challenge

“Mining is not a well understood sector in Kenya, so it’s been a steep learning curve working through all the necessary requirements with the communities and government.”

to get all stakeholders to understand, accept and issue the various licences required, for example,” says Schwarz.

He continues that the company has been at the forefront of developing a modern mining industry in Kenya, coming to terms with all the local industry’s processes and issues.

Labour skills Another challenge for the company has been the shortages of certain skills in the country, requiring the use of expatriate staff with the necessary skills.

“We started off with 65 expats during

Ship-loading operations at the dedicated port facility

the commissioning phase and now reduced the number to 39 through a

Mukurumudzi River. The 8.5 million

structured approach to training and

cubic metre dam provides about

mentoring identified successors. We

20 000 m3 of water per day to run the

hope to decrease that number to 15

process plants. In addition to the dam,

over the next three years. This can be

the company also drilled a bore field

achieved through the multifaceted

for supplementary water, comprising

training effort into which we invested

four bore holes with a capacity of

nearly $1 million in the last financial

5 000 m3 a day. “The most important

year,” says Schwarz.

supporting infrastructure is the Likoni marine terminal, which cost $30 million

Health and safety

to build. This bulk storage and shipping

‘Safety is the Base Way’ is the company

terminal is located approximately

slogan and it clearly pays off, as the

50 km north of the mine site. Making use of conventional conveyor systems, the mobile ship

company has recorded only three losttime injuries in over 14 million man-hours

Offloading of mineral concentrate at the dedicated port facility

worked since commencement in October 2011, equating to an overall lost time injury frequency rate of just 0.22.

Future plans The current resource is relatively small,

The heavy mineral concentrate stockpile

if one looks at the life of mine being 13 years. “Therefore, the objective of Base Resources is to look further afield for potential acquisitions and developments, to grow the company beyond the life of the Kwale Project. Our strategic development plan will be looking at Africa and beyond for opportunities,” concludes Schwarz.

The heavy mineral concentrate stockpile

In sid e M in in g 0 1 | 2016

13

Prestigious Projects

Creating storage

initiatives T

HE MAIN REASON for additional

the upgrading of the thyristor panels,

storage space in the first place

changing the tipping system from con-

was the risk between the rate

ventional camelback system to an hy-

of hoisting and the rate of pro-

draulic tipping mechanism and increas-

duction. If a day was lost in a week, for

ing the payload from 16 to 19 tonnes.

whatever reason, the management had

This changes on the winder resulted in

to r sacrifice reef development or waste

an 20% increase in hoisting capability,”

being hoisted to the surface in order to

says Pretorius.

ensure reef is hoisted.

Although it may sound like a simple

Backtracking a bit – let’s look at the silo

challenges to take into consideration.

designs. The top and bottom of each

“With the silos, we had to extend the cur-

funnel shaped silo is small – only 2 m in

rent conveyor system and, we thought

diameter – while the middle of the silo is

that, while we were at it, we might as

6 m metres in diameter. The entire height

well redesign the skip to address shaft

of each silo is 42 m, with a capacity of

safety as we had previous incidents with

1 600 tonnes each.

the skip opening in the shaft or hook-

During the construction of the silos, the

ing onto the shaft steelwork,” explains

contracting company inflated balloons

Reghardt Pretorius, manager: Engineer-

to the size of the opening of the silos to

ing at Beatrix Operations.

stop any material from injuring people at

“But, it didn’t stop there. We thought

14

The silos

solution to a problem, there were a few

the bottom level. A safety net was in-

that, if we look at a new skip, what can

stalled and the area was barricaded off.

we do to maximise the output with in

“The company then drop-raised the silos.

the current infrastructure without major

It was the first time that they construct-

changes to the winder. This resulted in

ed, blasted and drilled in this way. And,

Ins i de Mi n i n g 0 1 | 2 0 1 6

In the quest to create more storage facilities underground to reduce business risk, the engineering team at Sibanye Gold’s Beatrix Mining Operations Shaft 3 came up with a new idea.

They created two silos between levels 26 and 27.

By Mientjie Kleinhans

Production figures for Shaft 3

• 265 000 m2 2015 annual stoppage • 1 800 000 tonnes hoisted • 5 100 tonnes recovered ore • 15.2 km development. Broken down as • 10.6 km off reef • 4.6 km on reef • Stoping width 174 cm • Blasted grade 5.7 gram/tonnes • Blasted ore 990 cm/gram/tonne

Prestigious Projects “The benefits of the new skip design include safety improvements and a 20% increase in the winder’s capacity.”

the load, but also a much longer working life, which will be a huge cost saving taking into consideration current life

A conveyor belt similar to the one that will be transporting the ore from the bottom opening of the silos on level 27

spans and rope costs. The secret is all in the construction of the rope. Where they previously used a triangular strand, the new round-strand rope is a physically manufactured rope, specially designed for this winder machine.

The rope consists of many more, and thinner, wires made of a different type of steel. Although the cross section of

it was the first time we had seen a con-

the rope remains the same, it has a fi-

tracting company being able to do that

bre base core, meaning more strength.

accurately,” says Mannas Fourie, mining

Although the initial capital outlay is

manager and team captain, Mining Unit

higher, the rope has many benefits, such

1.’ Pretorius explains that the benefits of

as 120 000 cycles – compared to the

the small top and bottom silos means

75 000 cycles of traditional wire ropes.

less construction and being more sup-

Pretorius explains that, if broken down

portive than having a 6 m hole that has

to rands per cycle, it is actually not

to be covered with steel. “The smaller

that expensive.

the hole, the safer it is to work on. It is also safer for scaling on the sidewalls,”

New skips

says Pretorius. “If the bottom part is big-

Moving away from old technology,

ger, it means that one has to design the

where the skip had the potential to

steelwork to cater for ore travelling 35 m

open in the shaft, the team has been

from the top to the steelwork at the bot-

looking at the new winder-skip technol-

tom. The funnel effect stops the ore and

ogy. The skip is fixed in a certain position

it becomes a natural deadbox for

with a door on the bottom side with a

the ore,” explains Pretorius.

The silos create extra buffer capacity to

hydraulic power pack.

system, it builds up into the stope and creates its own risk,” tells Reghardt. This

This means the skip enters in

necessitated the development of the

a straight line, never moving

two silos.

hoist at any point in

from the frame, and goes

time and they are in

into the tipping mech-

Future plans

line with the stations’

anism where the door is

The future for the Beatrix Mining Oper-

main tips. This allows

pulled open for the ore

ations includes the depth extension of

them to tip in ore

to exit. “With this design,

the mine with the Bloemhoek project.

from level 26. This will create a flooded suction for the winder, enabling

there is no hooking on the

This project will extend the life of mine to

steelwork,” says Pretorius. The

2041, meaning an additional 20 years to

other benefit of the design is that,

them to hoist continuously and tip

because of a positive pressure from

without any risk. “Should we have a de-

the ore, the ore lays on top of the door,

lay, we have the extra capacity to deal

keeping the door shut. The skip always

with the additional ore, as required, for

stays in an offset position. A positive

the day,” says Pretorius.

force is needed to open the door to

New rope technology

the current expected life of mine.

extract the ore.

“The actual benefit of doing it like this

The shaft normally operated at a 14

is a safer skip design and an increase in

to 14.5 tonne factor, meaning that

the winder’s capacity of at least 20%,”

each skip hoisted weighed at least that

says Pretorius. “Next, we looked at buffer

much. The new skip increased the skip

capacity – how we can accommodate

factor to19 tonnes,. “But, to do that we

more production from the level, store it

needed a wire rope that could handle

and still hoist it. With our main produc-

the weight, without changing any of

tion coming from levels 25 and 26, if we

the winders major parts this meant we

don’t hoist continuously, there is always

had to look for a rope that will provide

a buffer. If we don’t put the ore into the

a breaking force to comply to all the statutory requirements but remain the same in size, hence the new rope,” says Pretorius. The new rope will give us the higher breaking force that is required for

ABOVE (left to right) Mannas Fourie, Liemiso Molelengoane and Reghardt Pretorius

The top opening of one of the silos still under construction

In sid e M in in g 0 1 | 2016

15

Prestigious Projects

Excellent results

from FFG T

HE COMPANY reclaims sand and

pipeline starts at the Crown Complex,

slime from old mine dumps to ex-

where 300 000 tonnes of sand and slime

tract gold for gold production. The

are pumped monthly to City. At City, an-

sand first goes through a milling

other 300 000 tonnes are added to the

process, while the slime goes directly into the FFG system. Although the system has

From Elsburg, 1.2 million tonnes of ore

been in operation for a year, it was effec-

per month joins the pipeline corridor in

tively set in operation two years prior. Dur-

two separate pipes, which then flows

ing the initial start-up stage, the system

to the ERGO gold processing plant

caused some problems and the team of

treating a total of 1.8 million tonnes per

engineers had to find the problem. Due

month prior to discharging its tailings on

to its extensive area of operation, it was

the Brakpan tailings dam. Finally, water

quite difficult to find the problem at first.

is pumped all the way back from the

2015. Each pipeline consists of a 600 nb

“It took us a couple of months to rectify

Brakpan tailings dam to the various rec-

steel pipe with a high-density polyure-

the problems, but now the system is fully

lamation sites, forming a closed circuit

thane liner, and carries about 600 000

operational,” explains Jaco Schoeman,

of water.

tonnes a month. A monthly total of 2 mil-

operations director, DRDGold.

Pipeline

Process

By Mientjie Kleinhans

lion tonnes of ore enters the FFG plant.

After some investigation, the team

The sand dumps are reclaimed using

realised that the additional gold could

The three main reclamation sites that

front end loaders and slime is reclaimed

be liberated from the pyrite in the sand

feed the Brakpan process plant are the

using high-pressure water to create a

and slime and that flotation specifically

JCC dumps (3A2 and 3L2) near Soccer

slurry prior to being transferred in three

targets the pyrite to extract the gold.

City, the 3L42 slime dump near the City

separate streams to the FFG plant, with a

“This was a big challenge for us, as we

Plant and the Elsburg reclamation site

fourth stream from the Van Dyk reclama-

couldn’t leach all the gold contained

next to the N17/Rondebult off-ramp, all

tion site – the latest slime reclamation site

in the pyrite, and we couldn’t just mill

located in the Witwatersrand area. The

that was commissioned in September

1.8 million tonnes of ore, as the electricity

Some of the flotation tanks in the system

16

pipeline, which then flows to Elsburg.

DRDGold developed a flotation and fine-grind (FFG) circuit to extract gold from old mine dumps, at a project cost of R305 million. This excludes the 50 km Crown-Ergo pipeline but includes the automated system assisting the process that targets the gold in the ore.

Ins i de Mi n i n g 0 1 | 2 0 1 6

Prestigious Projects

costs would be too high. We simply had

before rejoining the flotation tail entering

to find a way to isolate, concentrate

the low-grade carbon-in-leach circuit.

and liberate the gold contained within

Once processed through the low-grade

the pyrite structure, and this is where our

CIL, material is disposed of on the Brak-

research and development team found

pan Tailings Storage Facility.

the solution,” explains Schoeman.

He explains that, with the FFG process, float concentrate goes through a thick-

The loaded carbon from the CIL circuits

above left to right Pyrite concentrate generated from a flotation cell Men at work in the centralised control room Dilution water being added prior to flotation

is transferred to the elution plant where gold is eluted from the carbon, recovered

exactly how much power each piece of equipment is consuming at any given

ener, then through a vertical fine grind

“The only way to extract additional gold from the pyrite mineral is by ‘cracking’ the ore particles, so that the cyanide can dissolve the gold.”

time of day. With this information, we are

says Schoeman. The material then enters

through electro-winning and smelted to

Lessons learned

the carbon-in-lead circuit, where oxygen,

produce a gold bar. “This gold is about

“When we initially introduced the FFG

limestone and cyanide are added in the

85% pure gold with the balance made

circuit, we experienced a number of

leach tanks. From here, the material goes

up of silver, nickel, copper, iron and other

integration issues. Due to the additional

to a carbon-in-pulp circuit that contains a

impurities. The FFG process in its current

complexity introduced, we had to review

high concentration of activated carbon,

format was finally commissioned in De-

each process change, section by sec-

cember 2014,” explains Schoeman.

tion. It took us a few months to identify

mill. The material enters the mill from the bottom and flows out at the top.

Small beads, with a diameter of approximately 2 mm, lie on top of each other and the rotating discs cause vibration of the beads as the material passes through the mill.

As the material passes through, the ore is reduced from 80% passing -35 μm to approximately 90% passing -22 μm. “This is the most feasible way to extract the gold – by ‘cracking’ the ore particles – so that the cyanide can dissolve the gold,”

SOME FACTS

• The Brakpan process plant is possibly one of the largest in the world • The 50 km Crown-Ergo pipeline corridor links all the assets • The pipeline upgrade cost R260 million

able to manage the plant efficiently. In times when the commodity prices are extremely low, we will use this information to switch off certain sections of the plant and only restart when it is economically feasible again,” says Schoeman.

The automation system being in place means that data is transferred every two or three seconds to the mainframe, which processes all the information, enabling the team to make informed decisions.

and rectify the problems. Introducing var-

Automation

ious changes simultaneously in a complex

What makes this project even more inter-

process makes it difficult to identify the

esting is the automation of the process,

root cause of a problem. From now on,

controlled from a centralised control

we will make one change at a time and

room.. “With this system, we can imme-

monitor the specific process; only once

diately identify a problem, implement

the process works without any further

corrective action, and analyse real-time

hassles will we make the next change,”

data and statistics from the automated

explains Schoeman.

system,” says Schoeman. This is ideal in such situations as load-shedding.

Highlights of the project

“Through our curtailment agreement

Some of the highlights that the company

with Eskom, we receive notification

has seen include an increase in gold pro-

to reduce power consumption two

duction and a decrease in residue grade

hours in advance.

leaving the plant; an increase of tonnag-

“Real-time monitoring of our power con-

es processed; and the most important

sumption allows us to reduce the exact

highlight is that the company has been

load, depending which load-shedding

fatality-free for over four years. Other

stage it is, by switch off specific pieces

highlights in the project include financial,

of equipment to save the required elec-

environment, human resources and so-

tricity. As a matter of fact, we also know

cial capital highlights.

In sid e M in in g 0 1 | 2016

17

Prestigious Projects

Unique onshore

Eskom annually spends over $2 billion on diesel to minimise load-shedding – a clearly unsustainable approach. With natural gas offering an attractive alternative, at a fraction of the cost of diesel, a recent gas discovery by Afro Energy has the potential to permanently change the face of South African coal mining and energy production.

By Mpinane Senkhane

gas set to soar A

FRO ENERGY, a joint venture

by the Mineral Petroleum Resources

extraction of CBM (coalbed methane)

between Badimo Gas and

Development Act of 2002. However,

from the coal deposits underground. It

Kinetiko Energy, currently

to gain access to land, the company

was during this process that Ncube estab-

owns and operates the Am-

had to additionally conclude an access

lished that South Africa had a scarcity of

ersfoort project, in Mpumalanga, as well

land-user agreement with the farmers

local experts to carry out the geological

as its adjacent applications (Volksrust)

who own the land. After almost a dec-

tests necessary for this type of explora-

– where the company has made an in-

ade of research and grappling with legis-

tion. But, with the help of American geol-

credible natural gas discovery. Recently,

lation, Ncube attained over 1 400 km2 of

ogist Paul Tromp, a specialist in coalbed

Afro Energy showcased to Inside Mining

exploration rights in the Amersfoort and

methane gas, the exploration took off,

the company’s test boreholes on the site

Volksrust areas. He described how the

uncovering a world of possibilities. How-

and detailed plans to further develop the

initial interest for exploration was for the

ever, it was during the drilling that the

project. At Amersfoort, approximately 350 km from Johannesburg, Donald Ncube, executive chairman of Badimo Gas and Afro Energy, shares the process he embarked on in a bid to attain exploration rights, and the challenges associated with a task of this magnitude.

Exploration Natural gas is a fairly unexplored resource in South Africa. Ncube described the difficulties the company encountered in securing the exploration rights to drill gas and the access to the property to be drilled. To conduct a drilling program for gas, the company had to secure exploration rights, which are regulated

18

Ins i de Mi n i n g 0 1 | 2 0 1 6

Natural gas is extracted at shallow levels of 150 m to 500 m, allowing for use of conventional technology and limiting the environmental, safety and health hazards associated with fracking

team discovered the natural gas, before even reaching coal levels. “Beginning in late 2011, we were exploring for CBM and ended up also finding natural gas in sandstones. The gas was trapped by water less than 300 m underground, so we needed to extract the water – that way, the gas escapes. Essentially, we had to become a water company before we could become an energy company,” Ncube explains.

It was during the exploration stage, when seven test flow boreholes were sunk in Amersfoort and another one in Volksrust, that the gas was found – not only an astonishingly pure methane gas (at 98%), but also in large volumes. Previous tests

Prestigious Projects presented itself as potentially favourable

Table 1 On-site methane quantities in coalbed methane and sandstone

for shale gas, with several companies

Contingent Resource (100% Gross) 1c (Bcf)

2c (Bcf)

3c (Bcf)

CBM

627.5

1.110.2

1.726.7

Gas in Sandstone

150.7

372.5

791.0

TOTAL

778.1

1.482.7

2.517.7

extracted at shallow levels of 150 m to

Gas in place (100%)

1c (Bcf)

2c (Bcf)

3c (Bcf)

500 m, allowing for the use of convention-

CBM

967.1

1.689.4

2.616.7

al technology – limiting the environmen-

Gas in Sandstone

292.6

706.3

1.450.6

TOTAL

1.259.7

2.395.8

4.067.3

applying for permits to explore for shale gas using hydraulic fracturing (also known as fracking). Afro Energy’s natural gas is

tal, safety and health hazards associated with fracking.

“With fracking, you are looking at levels more than 1.2 km underground,

revealed that there was a 50% chance

company plans to initially sell the gas to

where you need to use water to blast,

that there could be about 2 395 billion

industry off-takers, but the prospect could

which will subsequently release the gas.

cubic feet of gas in the licensed areas.

shift the energy conversation away from

With what we’re doing, there is no blast-

However, there is currently a 90% chance

coal and diesel in the country. Among

ing required,” explains Ncube. In this

that it contains at least 1 259 billion cubic

a plethora of uses, methane gas can be

case, conventional gas flows from the

feet of gas. “In reality, these numbers are

added to the coal that is burnt at coal

sandstone adjacent to the coal seams,

probably much higher,” Tromp insists.

power plants, making it possible to then

present across the entirety of tenements,

use a lower grade of coal, which has

providing the company with the oppor-

been a topical concern following the

tunity for quick potential revenue from

The geology in the Mpumalanga area

recent Optimum Coal-Eskom develop-

the sandstone long before it gets down

allows for a multiple-well approach,

ments. Afro Energy found this gas at the

to CBM extraction levels. Afro Energy,

eliminating reliance on so-called ‘one-

heart of South Africa’s coal-based ener-

together with its strong technical team,

well’ success, which is referred to as a

gy and power generation infrastructure,

is already embarking on the next phase

‘resource play’ in the petroleum industry.

within close proximity to major industrial,

of exploration and development, raising

Sustainable well flow rates from the pilot

mining, manufacturing and high-density

the prospects of future revenue, and

test wells, over the test period, would

residential areas, providing the company

subsequently creating new prospects for

have had an approximate six-month pay-

with access to multiple, economically

energy in South Africa. Ncube stresses the

back period at the current South African

viable revenue-generating options. The

importance of building relationships with

gas price of about $10/GJ. One of the

Brakfontein farm, where some of the test

pilot test wells flared over 26 Mmcf in six

boreholes are located, shows no visible

months during an extended well flow

mining activity and seems completely

test. If the gas had been sold under pre-

undisturbed, with nothing but a pump

vailing South African gas prices, it would

and steel pipe peering out of ground. It

have generated revenue of $260 000.

is when the gas whistling out of the pipe

As is, Afro Energy has acquired a bulk

is set alight that the magic happens – an

sampling permit from government, which

incredibly hot flame materialises, seem-

allows it to sell the gas from the existing

ingly out of nowhere.

Potential

and proposed wells in the two licensed

ABOVE LEFT TO RIGHT Technique for drilling test wells using local contractors Test flow gas well (lower right) is controlled and measured by this compact surface installation. Initial gas flows are flared but will soon be sold into the local market Donald Ncube and geologist Paul Tromp

areas in Amersfoort and Volksrust, con-

Zero fracking

host communities – in this case, farmers

sequently allowing trial production and

Afro Energy has, through its discovery,

in the Mpumalanga area. “We had to

sales to generate early revenue in 2016.

pitted itself as the most advanced on-

go through the farmers, explain to them

This will assist in generating revenue for

shore gas player in South Africa, and

what we are doing, and how this will af-

the first two years of operations, until the

not a minute too soon. With oil prices

fect them. We had to build relationships

production licence is awarded. The bulk

on the rise and the value of the rand

with them (the land owners),” Ncube

sampling permit allows Afro Energy to sell

sinking to further lows, the conversation

says. The prospects this project holds are

one million gigajoules of natural gas over

regarding alternative energy options has

encouraging, particularly with the current

this period while the process of obtaining

become exceedingly pertinent over the

energy crisis looming over the country.

the production licence continues. The

last decade. The Karoo has, in the past,

Afro Energy has indeed struck gas gold.

In sid e M in in g 0 1 | 2016

19

thought leaders

A BRIGHT

future beckons

Embracing up-andcoming talent and giving achievers the room to grow is putting SRK ahead of the curve, and bodes well for the company, the economy and the future of engineering’s contribution to global socio-economic development.

ABOVE (left to right) Daniel Avutia, geotechnical engineer Hartley Bulcock, senior hydrologist Paul Jorgensen, environmental scientist Joseph Muaka, mining/ geotechnical engineer Edrie Du Toit, civil engineer Joseph Mainama, principal mining engineer Vis Reddy, managing director and principal scientist Philani Mpunzi, mining engineer, SRK Consulting SA

20

Ins i de Mi n i n g 0 1 | 2 0 1 6

Y

OUNGER TALENT at SRK Consult-

Flying high

ing (SA) is energising the busi-

High-flyers within the firm have notched

ness with drive and enthusiasm,

up various professional and academic

as the global firm of consulting

achievements, highlighting the depth of

engineers and scientists attracts and cul-

knowledge. SRK geotechnical engineer

tivates industry’s best engineering and

Daniel Avutia was the only presenter

scientific brains across its wide range

from Africa at the Global Geotechnical

of disciplines.

Conference in Shanghai, China, in 2014

“SRK has always been an entrepreneur-

– and was honoured by having his paper

ial environment, based on professional

selected as one of the event’s best. As

integrity and the highest quality stand-

a result, it went on to be published in a

ards,” says Vis Reddy, managing direc-

special geotechnical publication of the

tor, SRK. “So, the culture of our workplac-

American Society of Civil Engineering.

es is attractive to younger people who

In 2015, he won the National Institute

want to stretch themselves and explore

of Materials, Minerals and Mining (IOM³)

their particular specialisations.”

Young Persons' Lecture Competition and

Its global network of offices, which

represented Africa at the World Champi-

has expanded to six continents over

onships in Dublin, Ireland, with a lecture

the past 40 years, comprises over 50

on the analysis of sinkhole propagation

offices – each with substantial employ-

in South Africa.

ee ownership. “We try to create a space

To crown his achievements and

in which our up-and-coming scientists

contributions towards the engineering

and engineers feel both supported

fraternity, he was later selected by the

and challenged,” says Reddy. “They

South African Institute of Civil Engineers

are mentored in the application of our

as the SAICE Young Civil Engineer of the

stringent benchmarks in every project

Year for 2015 – an award to promote

they work on, while, at the same time,

excellence in the profession and raise

encouraged to extend the boundaries

awareness of civil engineering contribu-

of best practice and exploit the value of

tion to society. Avutia also sits on SAICE’s

relevant technologies.”

Geotechnical Division committee. “The

thought leaders Intern(al) excellence The company’s quest to be an employer of choice has attracted top students from across borders. Mining and geotechnical engineer Joseph Muaka was Student of the Year at the University of Lubumbashi’s Faculty of Engineering, bemost fulfilling part of my

fore working for mining companies in the

work is really the prob-

DRC, and then relocating for a job at

lem-solving, which often

Mintek. Joining SRK South Africa’s Johan-

involves working with

nesburg office as an intern, while com-

communities and helping

pleting his MSc at Wits University’s School

to improve living condi-

of Mining Engineering, Joseph continues

tions,” says Avutia.

to raise the bar – most recently, with a

Young minds, new ideas Understanding the needs

presentation to the Southern Hemisphere International Rock Mechanics Symposium on numerical modelling.

The internship programme at SRK –

of the younger staff and

partnering with institutions like Wits

adapting aspects of the

University – also allows MSc graduates

organisation accordingly

to become mentors to newer interns.

are vital for any compa-

Philani Mpunzi, who completed his stud-

ny with a vibrant and for-

ies in 2011 at Wits, is now a specialist 3D

ward-looking ethic, ac-

modeller for SRK and helps interns to

cording to SRK corporate

make the most of their time while opti-

consultant Roger Dixon.

mising their contribution. “Having worked

“This requires a culture of

in Zimbabwe’s mining sector for six years

listening and openness

as a production supervisor and mining

to new ideas,” says Dix-

planning engineer, I appreciate being

on. “This means that the

able to share my experience while con-

learning environment we

tributing to the development of young-

provide must be effective, as it is vital to be able to demonstrate trust in our engineers’ abilities and let them express their talents in their work.” Civil engineer Edrie du Toit says she values the emphasis on innovation, “The values at SRK allow us to be more innovative with our designs and solutions,” she explains. “Engineering is a dynamic field, especially with changing legislative requirements and the need to protect the environment; embracing new methodologies means that we can constantly improve our ability to add value to our clients’ projects.”

With geotechnical engineering expertise in mining, slope stability, saprolites, tailings dam designs and abandoned mine rehabilitation, she highlights the benefits of the trust and responsibility

er rock engineers,” said Mpunzi.

“The learning environment we provide must be effective, as it is vital to be able to demonstrate trust in our engineers’ abilities and let them express their talents in their work.”

afforded to younger employees by the

The range of disciplines encompassed

firm – including the ability to engage

by the company’s broad service offering

directly with clients.

gives plenty of opportunity in water, en-

“Being in direct contact with clients

vironmental and social spheres. Dr Hart-

speeds up the data distribution channels

ley Bulcock is a hydrologist at SRK, hav-

between the client and the person who

ing joined SRK in 2014 after completing

is ultimately responsible for getting the

his doctorate – and lecturing in hydrolo-

work done,” Du Toit states. “It also gives

gy – at the University of KwaZulu-Natal’s

us the opportunity to show them, first-

Pietermaritzburg campus. His research

hand, what we are capable of – creat-

and papers have been presented both

ing a sense of trust between the parties.”

locally and internationally, and have

employee awards The South African Institute of Civil Engineers selected SRK geotechnical engineer Daniel Avutia as its SAICE Young Civil Engineer of the Year for 2015. Avutia recently also won the IOM3 Young Persons’ Lecture Competition and represented Africa at the inaugural RockBowl lecture competition at the ISRM Congress in Montreal, Canada. He earned his registration as a professional engineer in August 2015.

SRK hydrologist Hartley Bulcock was awarded the Emerging Scientist and Water Resources Engineer prize at the 2011 South African National Hydrology Symposium in Grahamstown. He won the Water Research Commission’s prize for the top young scientist presentation at the symposium a couple of years before – having also earned the mantle of Top Hydrology Student at the University of KwaZulu-Natal. earned him some early recognition at the biannual hydrology symposiums (see fact box). Environmental scientist Paul Jorgensen is another award-winner at SRK, having been awarded a Green Talent Award in 2010 by the German Federal Ministry for Education and Research – a global distinction that recognises outstanding scientific talents in the field of sustainability research.

His focus is to work with clients in the interface between natural and social capital, and how this can generate positive change and benefits for business and society. Already having accumulated substantial experience in the diamond, gold and platinum sectors, principal mining engineer Joseph Mainama joined SRK in 2013, bringing added expertise in business and project management, feasibility studies and reviews. By no means a new entrant, Mainama still represents a vital younger element of consultants in an industry that is often over-reliant on late-career experts. SRK’s intellectual capital is growing daily, as the knowledge and experience of the veterans is shared with earl-career engineers, who must take the baton and keeping raising the bar.

www.srk.co.za

In sid e M in in g 0 1 | 2016

21

mechanised machinery

Can mechanisation save

SA’s ailing mines?

With steadily falling productivity on South Africa’s mines and a commodity price slump putting thousands of jobs on the line, mining companies have no option but to grasp the nettle of mechanisation to put this vital sector on a sustainable footing.

By Dr Declan Vogt

I

T IS CLEAR THAT the most recent

gold mines, however, present particu-

preferences are chang-

commodity boom was good for min-

lar problems: the ore itself is hard and

ing and these are not the

ing profits, but masked a distressing

abrasive, so rock cutting is not economic

kinds of jobs that will attract work seekers

erosion in productivity, which now

at present. Conventional drill-and-blast

into the future. Unemployment is also a

threatens the survival of many mines;

mining can be mechanised, but orebody

national issue, and the mining sector is

in the gold sector, for instance, labour

geometry is a challenge; the metal-bear-

not capable of solving it alone. If mech-

productivity has declined 35% since 2007,

ing reefs are narrow, varying from centi-

anisation can keep mines open, there

according to research published by EY

metres to about a metre in thickness. The

will be economic benefit to the country

this year. We cannot survive on our cur-

reefs dip at between about 10 degrees

and to the neighbouring communities.

rent course. At today’s prices, most of

and 30 degrees – too steep for easy use

There will be fewer miners, but they will

our mines are not profitable. Among the

of wheeled vehicles, but too

explanations for the high cost of mining

level for broken rock to flow

are the following:

on its own.

•m ines are getting deeper • infrastructure is old •e nergy costs have rocketed •c onstrained and unstable elec-

Despite the challenges, there are extra-low- and

tricity supply has undermined

ultra-low-profile machines

operational efficiencies

available to mechanise the

• l abour costs have exceeded inflation for many years.

22

Possible solutions

tasks of drilling, cleaning and supporting the face. They have

As we have little control over global

started to be used in platinum

commodity prices, the only solution is

mines, and roughly 30% of cur-

improved productivity. It would be wrong

rent underground production

to suggest that there has been no pro-

now comes from mechanised

gress in mechanising mines in South Afri-

areas. Such equipment has

ca. Neither is it true that mechanisation

not yet been widely deployed

is a panacea on its own; enhancing pro-

in older mines that were de-

ductivity requires integration and coordi-

signed for hand-held drill and

nation of designs and systems, along with

blast techniques, for reasons

a change of mindset and skills profile. It

mainly related to labour costs.

is a complex, lengthy and usually expen-

What, then, is required to make

sive process. Without it, however, many

mechanisation work more

more mining jobs are at risk than those

broadly in South Africa’s min-

currently on the chopping block. Within

erals environment? Clearly, the

certain commodities, mines have seen

impact of machines on em-

substantial technological change in min-

ployment needs to be negoti-

ing methods. Just about the whole coal

ated by mining’s stakeholders,

sector is mechanised, and a number of

but there is little to commend

platinum mines have been designed

the experience of being a

and operated to run as mechanised

manual worker in a labour-in-

operations. Orebodies in our deep-level

tensive mine; young people’s

Ins i de Mi n i n g 0 1 | 2 0 1 6

Gravity pipe installation at a remote mine

mechanised machinery be better paid and will spend their pay

FIGURE 1 South African gold production, 1910-2014

in the local area, sustaining at least some economic activity. Without the mine, that activity disappears altogether.

Mechanising mines means a change to a skilled, flexible workforce – a shift that has already been made in other local industries; South African car manufacturers, for example, are on a par with the best in the world. In a mine of the future, one operator will produce a significant portion of the mine’s total production, but that operator needs the skills and freedom to act to adapt the work plan as the situation changes. This level of skill and flexibility is orders of magnitude more complex than that of the traditional gold miner.

Appropriate technology Then there is the question of having the

mechanised by buying equipment –

conventional mining is different, where

appropriate technology for deep mines

perhaps some drill rigs and load-haul

a delay in fixing a problem generally

to mechanise, and the need to invest

dumpers – but that kind of mechani-

doesn’t have a major impact on the

sufficiently to develop, apply and com-

sation is unlikely to work. Mechanised

overall production rate. A key challenge

mercialise these solutions. The efficacy

mines need to be designed differently to

for the sector, then, is the legacy of

of these solutions, however, depends on

labour-intensive mines, and they often

workers and managers in a conservative

the operational context, so they cannot

also need to be organised differently. For

industry, and moving them towards a

simply be imposed upon existing mine

example, they may need tunnels that

culture in which mechanisation will work

designs. Superficially, a mine could be

can accommodate large vehicles, and

best. Within a learning organisation,

ramps that are not too steep.

the will and ability to solve the tech-

But the real issue is the radical

nical issues will overcome the hurdles

cultural transformation in the

that remain.

workforce; there is a need for a new way of thinking. In

Systems approach

the manufacturing industry,

At the Centre for Mechanised Mining

there has been a worldwide

Systems, we follow a ‘systems approach’

shift to what is called ‘lean

– where a system consists of people,

manufacturing’. The lean

processes and technology – and use this

principles incorporate a strong

to act as connectors between mining

emphasis on teamwork, col-

companies and equipment suppliers.

lective problem-solving and

Often, a mine doesn’t fully understand

meaningful work.

the abilities of the equipment available,

Mindset change

while the equipment supplier doesn’t fully understand the mining problem. With our

Mechanisation needs a mind-

unique combination of mining, mechan-

set change: a mechanised

ical and industrial engineering skills, we

suite works best when every

can assist in bridging this gap. We have a

part of the operation is coor-

proven track record of generating various

dinated towards the overall

options during pre-feasibility studies that

goal of higher production.

have the potential to turn a loss-making

Once a mine adopts a level

mine into a profitable operation, simply

of automation, the issue of

by lateral thinking around the problem.

coordination becomes critical.

We also research issues that are shared

There is a close relationship

by the mining industry and its suppliers,

between the pieces of equip-

such as skills. Mining still provides about

ment at work and the fast

15% of South Africa’s gross domestic

pace of operation means that

product and, with multiplier effects,

problems need to be diag-

significantly influences our success as a

nosed and solved very quickly

nation. Mechanisation will help our deep

or substantial production will

mines to maintain this contribution. It’s a

be lost. The mindset within

prize worth fighting for.

In sid e M in in g 0 1 | 2016

23

mechanised machinery

Harmonising

man and machine As mines introduce remotely controlled equipment, upskilling workers to operate these machines is seen as a potential solution to curbing job losses, creating a steady stream of revenue and cutting significant costs. Without a sustainable solution, fresh labour sector disputes are likely to spark. By Mpinane Senkhane

T

24

HE DISCUSSION around the mech-

African mines. Inside Mining spoke to

the physical efforts of employees, while

anisation of mines is a long-stand-

Andrew Lane, leader: Energy and Re-

improving productivity and rendering

ing one, particularly between

sources, Africa at Deloitte, and Sietse

working conditions increasingly safe and

the private and public sectors.

van der Woude, senior executive: Mod-

healthy,” Van der Woude explains, add-

In order to remain competitive in a

ernisation and Safety at the Chamber of

ing that mechanisation should not be

burdened industry, mines have started

Mines, about the implications of mech-

seen solely as the provision of mechani-

to move towards mechanising mining

anisation and the options of upskilling

cal equipment, but as part of integrated

operations. Historically inexpensive and

workers on mining operations. “Mecha-

strategies to make mines healthier, safer

abundant labour has led to the com-

nisation has long been viewed as a pos-

and increasingly sustainable. Compa-

mon use of huge workforces on South

itive development insofar as it lightens

nies need to start mechanising. “In fact,

Insi de Mi ni ng 0 1 | 2 0 1 6

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mechanised machinery

Should the current paradigm of machine complementing man be turned on its head? in a bid to reduce reliance on a large-

gold mining industry, is to mine at ev-

Challenges

ly unskilled workforce, some already

er-increasing depths and extract all the

Training personnel is a challenging

have,” Lane asserts.

ore from support pillars without affecting

option for the industry, as the move to

their strength. What this implies is that

mechanisation is not yet considered a

our mines operated remotely would be

universal one. It is mostly in coal mining

The majority of workers in mining oper-

producing ore at depths at which min-

where mechanisation has been em-

ations are unskilled and the option to

ers could not work safely or healthily.

braced to a significant extent. Despite

Upskilling the unskilled

train all workers for upskilling purposes

the reluctant uptake, mechanisation is

is daunting to say the least – keeping in

Curbing losses

mind the complexities associated with

“This does not necessarily imply job loss-

mining machinery being at significantly

mining machinery technology. To this,

es; as production increases, people will

reduced risk of accidents. Using people

Van der Woude says, “Upskilling is an

be required to run the machinery from

in deep-level operations is a significant

option that is determined by the sort of

remote locations. What it will call for are

challenge for mining companies. In

mechanisation involved.

the skills needed to operate the equip-

addition to the safety hazard, mines

“When new machinery is introduced,

a safer option, with personnel operating

ment. Where jobs are affected, reskilling

need to make the environment at those

training in its operation is essential – not

for alternative jobs would need to be

depths suitable for workers – in that ef-

only to ensure that it is operated pro-

considered,” Van der Woude stresses.

fort, another expense arises.

ductively but, more importantly, that it is

Lane agrees that mechanisation does

operated in a manner that adds to safe and healthy working environments.”

Contrary to popular belief, the negative impact the strikes had on productivity, particularly in platinum and gold, has not been the main indicator for the need to mechanise. Lane explains that the move to alternative mining methods is especially driven by the economics of

Mechanisation does not necessarily mean that jobs will be lost, but rather redefined and moved around

For mechanisation to be effective, a specific skill set is required. Van der Woude outlines that skills training is an integral part of a mine’s operation and an integral part of an individual’s career progress. It is something that is continuous, and the mining industry is fully committed to it. Better-trained employees would lead to increasingly safe, healthy and productive working environments.

the mining industry; however, he urges

not necessarily have to translate into job

There is no black and white path to

that the drive to mechanise started long

losses, “Just think about all the sectors

mechanisation – technically, socially

before the 2014 platinum strike.

that supply the mining industry; think

or politically.

The National Union of Mineworkers

about beneficiation. If you look at that,

While, overall, there have been sub-

(NUM) and the Association of Mine-

it actually means that jobs will not be

stantial productivity improvements

workers and Construction Union (AMCU)

lost, but rather moved around,” he sug-

over the last few months, more needs

have been vocal regarding the resist-

gests. Wholesale job losses occur when

to be done to keep the South African

ance to mechanise mining operations,

a mine reaches the end of its economic

mining industry competitive. Job losses

based on the assumed impact it would

life and this is exacerbated during eco-

are highly contested, owing to the high

have on the labour force and the as-

nomic downturns, when commodity

unemployment rate, which mine oper-

sumed job losses.

prices decline and costs rise, often

ators, their workforces and the unions

resulting in the premature closure of

undoubtedly need to take into account.

that perhaps mechanisation need not

operations or operations being placed

Mechanisation is crucial if South Africa’s

translate into job losses – suggesting

on care and maintenance. However,

mining industry is to remain productive,

that mechanisation, particularly as the

Van der Woude contends that mech-

profitable, safe, and healthy, so that it

mines introduce remotely controlled

anisation will allow for the extension of

can continue to offer satisfying jobs and

equipment, will call for upskilling opera-

a mine’s life, therefore maintaining job

careers, and provide benefits to

tors. “The overall aim, particularly of the

opportunities for skilled operators.

all stakeholders.

However, Van der Woude indicates

In sid e M in in g 0 1 | 2016

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mining & contracting

More than saving costs In times of economic uncertainty, it is not unusual for mining companies, relooking their budgets and spending, to question the value a mining contractor adds to a mine. Mientjie kleinhans investigates the benefits and disadvantages of outsourcing to mining contractors.

A

Each project is unique, with different challenges cash flow and converting capital spend into a variable operational expenditure,” write the authors.

Flexibility-based factors Mining is an industry with a number of variable influences, from geology and labour

STUDY WAS RECENTLY done on

capital efficiency-based factors, flexibil-

conditions to the seasons and commodity

a decision-making framework,

ity-based factors, competence-based

prices, write the authors. “Each mining

and the findings were pub-

factors, and relationship-based factors.

project is unique and presents its own

lished in the technical paper:

unique complexities and challenges. The

‘Outsourcing in the mining industry: deci-

Operational cost-based factors

sion-making framework and critical suc-

According to the authors, transactional

dependent, largely manual technolo-

cess factors’, by C J H Steenkamp and E

cost theory and the drive for efficiency

gies to automated methods, resulting in

van der Lingen. According to the authors,

have long been the dominant reasons

mining contractors partnering with equip-

their research confirms that there are a

for outsourcing. “Any organisation, but

ment suppliers to enable them to access

number of factors, including cost, to con-

particularly commodity organisations like

new technologies.”

sider when choosing between in-house

mining companies, strives to minimise

and outsourced mining contractors. The

production and transaction costs. Com-

Competence-based factors

objectives of the study were to:

panies sometimes outsource a function

The authors write that a company should

• determine whether mining is truly a core

to convert a fixed-cost cooperation into

look for opportunities to:

competency for a mid-tier geographical

a variable-cost operation, thereby mini-

• protect and develop its core compe-

commodity specialist and evaluate this

mising the risk of a negative profit margin

against the perceptions among man-

under low production volumes.”

agement in such a company • develop a decision-making framework

Capital efficiency-based factors

tendency is to move from labour-

tencies internally, even at a slightly higher transactional cost • balance and sharpen its competitive edge by outsourcing non-core compe-

for mining operations sourcing for future

“In mining operations, for example, con-

mining projects, which includes a priori-

ducting the functions in-house means

tised list of factors to consider

that the company needs to invest capital

Relationship-based factors

start-up in order to acquire a mining fleet

According to the authors, outsourcing, if

(CSFs) that should be adhered to if out-

and then periodically replace these assets

applied correctly, can create bonds and

sourced mining is the chosen option.

as they age, which requires additional

network an organisation in such a way

The strategic outsourcing decision factors

capital. A mining contractor will model

as to increase productivity. The strategic

that the authors highlight in the paper

this, and build the capital requirement

relationship between client and vendor

include operational cost-based factors,

into their variable rate, thereby smoothing

becomes quite important.

• determine the critical success factors

tencies to best-in-class service providers.

Contracting companies offer experience and skills

In sid e M in in g 0 1 | 2016

27

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mining & contracting Success factors

has to become more productive, reduce

The authors write that it is believed that

their unit cost of production, and avoid

the benefits of contractor mining are

expansion at all costs,” says Mapasa.

not a given, but are heavily dependent

Lourens says that mining companies need

on choosing the right contractor, setting

to invest in contractor specialities, such as

the appropriate incentives through contracting and implementing the business

GB0585 Cost and production efficiency are some of the reasons for outsourcing

core development, shaft-sinking services, specialised construction and equipping.

“In these applications, contractors are

solution correctly. The three categories of appropriate control mechanisms are

are incentivised or compete on volumes/

above the rest and, through this, im-

listed as process control mechanisms,

tonnes moved, rather than mining com-

proved production can be achieved by

output control mechanisms and social

panies that tend to receive revenue from

mining houses,” explains Lourens.

control mechanisms.

the market price of minerals they mine.

“In other words, the contractor is focused

Skilled workforce

on the costs and benefits from being pro-

“The quality of our people is the number

Khathutshelo Mapasa, executive officer:

ductive,” says Mampasa. Lourens agrees

one strategic advantage, as all other

Basil Read Mining, believes that there are

and says: “Due to the focused attention

assets can be acquired relatively easily.

a few benefits for mining companies to

and speciality on the specific task allocat-

It is how these assets are utilised, and

outsource to mining contractors. He says

ed to the contractor, the efficiencies be-

optimised, that gives companies the com-

Comment from mining contractors

that the first benefit is that the mining companies avoid upfront cap-

come higher and the quality of work increases dramatically.”

ital expenditure associated

Experience and technology

with owner mining, such as the cash flow benefit

petitive advantage. The ‘how’ is where the workforce makes a difference,” says Mapasa. Lourens agrees and adds that a skilled workforce is needed to ensure all safety standards are met with zero

to the client. The second

According to Mapasa,

potential accidents. Skilled workers lead

reason why Mapasa be-

experience is gained from

to a trust relationship in order to achieve

lieves mining companies

the various projects that

the required work as planned, with ex-

they have been involved

pected delivery dates, safely. “Training is

is that contractors offer

in and can be transferred to

a continuous process, which needs con-

experience from other

other projects. “This results in

stant attention and specifically ‘on-the-

current and past pro-

better executing, avoiding

job’ coaching and training,” says Lourens.

bad practices and imple-

Mapasa says that the training needs of

menting best practices. As

their workforce are tailored towards im-

contractors, we also rotate

proved performance.

should look at outsourcing

jects, which accelerates the learning curve and delivers efficient services to the client. “Also, contractors offer flexibility for the client to quickly ramp-up or -down, depending on the market,” says Mapasa. Louis Lourens, deputy-CEO of JIC Mining, reckons

“Starting up projects correctly is vital to enable operations to achieve set targets.”

Louis Lourens

key personnel across our

“So, the discussions about training start

portfolio of projects, which

with performance reviews of the individu-

accelerates learning from

als and the various teams,” says Mapasa.

mistakes,” says Mapasa. He

Both companies offer training facilities

adds that technology is key

in-house. What sets mining contractors

in enabling them to monitor

apart is safety, productivity, experience,

the performance of oper-

knowledge in the specific fields, trust

ations, so that they can im-

and, very importantly,

prove all the time. “We are

client relationships, says

benefit from mining contractors due to

able to communicate the performance

Lourens. As concluded

improved safety and focused production.

across the various support centres, short-

in the white paper, there

“Therefore, the mining companies experi-

ening our problem-solving cycle. Technol-

are a number of factors

ence improved efficiencies.”

ogy improves the way we capture data,

to consider in the deci-

with improved accuracy, and eliminates

sion-making process, and

human error. We also deploy technology

it may be beneficial for

How do mining contractors save mining

to enhance safety and environmental

a mining company to list

companies money? Lourens reckons

performance across our projects,” says

the important factors for

this is due to the fact that contractor

Mapasa. Lourens adds that experience

the company before em-

companies’ overheads are much lower

and knowledge of specialised work is key

barking on outsourcing to

than that of big mining houses. Mapasa

in the mining field. “If you start up projects

a mining contractor.

agrees and adds that the main area of

correctly, then the mining will be in a

cost-saving for the client is through pro-

very good position to achieve the targets

ductivity and efficiencies in operations

set,” says Lourens. Mapasa believes that

– that is the reduction in unit cost through

mining contractors can assist with growth

efficient and productive operations that

in the mining industry through productiv-

contractors are able to provide. Mam-

ity, meaning doing more with the same

pasa adds that, in general, contractors

for less. “Given the current depressed

offer more productive operations, as they

commodity prices, the mining industry

that mining companies

Cost savings

Khathutshelo Mapasa

follow the link Follow the link to the unedited paper: http://bit.ly/1O7AZNz

In sid e M in in g 0 1 | 2016

29

it & COMMUNICATION

Big data in mining Big data is definitely the latest buzz phrase all over the world, and it is also very applicable to the mining industry. Mientjie Kleinhans spoke to two specialists in their fields to hear what they think of big data in mining.

B

IG DATA IS a term very much

soon developed for the mining industry

used at the recent Bentley’s

and goes hand in hand with auton-

The Year in Infrastructure 2015

omous mining. Dave Body, solutions

conference, and the consen-

executive: Mining at Bentley, uses an

ABOVE Compiling a huge amount of data and then managing it to make better business decisions makes up part of big data

sus is that big data is here to stay and

operation centre in the West Australia as

large packets of data that need to

should be fully integrated in the mining

an example of where big data is used in

be in a system where the data can be

sector. Although there are a few defini-

the mining industry. “This remote oper-

interpreted, or also managing a lot of

tions for big data, it is generally agreed

ation centre consumes 2.4 terabytes of

data. “Otherwise one may end up with

upon that big data should be deployed

data per minute. That is big data.

a big pile of data that is really hard to

to make smarter decisions. Big data

Most of the data is time-based or

find,” says Albright. He says that one of

condition-based. It allows the operators

the big challenges for mining is the inte-

huge applications,

to make decisions from what they are

gration of data. Starting a new project

such as those

seeing in real time,” says Body. Kevin

tends to take a lot of time, and involves

Albright, global collaboration man-

setting up all the technology and get-

but the tech-

ager: Business Technology Solutions at

ting it to work.

nology was

Aecom, defines big data as capturing

originally started with

with Google,

“Big data needs to be effectively managed, otherwise its use is minimal.” Kevin Albright

By using specially designed software, one is able to look at the processes – what the processes for each step of the way are, mapping those steps, putting them into a template, and using the automated system to turn around the

In sid e M in in g 0 1 | 2016

31

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it & COMMUNICATION project quickly. “That is how we do project planning in 15 minutes,” says Albright. “The mining industry, as a whole, should be ashamed that more than 70% of new projects and capital projects are associated with mining fail. They either over-budget by more than 25% or their schedule slips down more than 25% – and they fail for a number of reasons,” says Body. He explains that one of the reasons is because of poor planning, or the initial pre-feasibility and feasibility studies on the infrastructure requirements are not done properly. The right

Definitions

• Big data: There are so many definitions for big data and it seems to evolve as well.

TechTarget explains: “Big data can be characterised by3 Vs: the extreme volume of data, the wide variety of types of data and the velocity at which the data must be must processed.”

• Optioneering: Bentley Systems introduced this term and defines it, in short, as “Engineering with options”.

1 petabyte = about 1 000 terabytes 1 exabyte = 1 billion gigabytes

and feasibility study, strategising and mine planning, mine operations, production and, finally, end results. Individuals can use and manage all the information, such as equipment performance, operation and maintenance. In the case of operation and maintenance, a mechanic would immediately know when the next service is due, what was replaced in the previous service, and what to expect from the machine.

In an autonomous mine, all the information from the various sensors on the equipment assists operators to operate

software programme looks at various

the machine optimally, and engineers

options and layers of the mine site and

can see how the machined performed, wait too long, it is going to cost you a

for instance. “Data gathering and

lot more money, because you will have

capturing is important, because the

to go back and gather the information

information is needed downstream.

“For instance, Bentley developed a

and fill in the missing gaps, as the peo-

You want to capture the information

product for materials handling, from

ple who created the projects may not

from phase to phase, as you don’t

conveyors and shoots to vessels taking

be around anymore.”

want to repeat the process and in-

the infrastructure associated with it.

Optioneering

the material from the crusher to the

“Big data is almost endless. And the

crease the cost. In the operations and

process plant, overland or over sea. The

data capturing should ideally start with

maintenance mode, for instance, one

software looks at the entire network of

the pre-feasibility study,” says Body.

needs the information to make business

materials handling, finding a solution by

“The mining industry is slowly mov-

decisions, financial decisions and fore-

looking at the pre-feasibility and feasi-

ing to autonomous mining,

bility phase, bringing in all the disciplines

meaning copious sensory

together in one solution,” says Body. This

information from oper-

software then offers options with differ-

ating equipment. All

ent layers, such as various cost factors.

the information from

And that is what is called optioneering

the sensors is already

– engineering with options.

big data. This portion

Mining industry

of big data should be used for analysis.” To give

casting decisions more effectively.

This means a system that can utilise that data to find what is

“Data capturing should start with pre-feasibility.”

David Body

In the mining industry, big data ideally

big data in mining a little

starts with a process of information gath-

more context – all information, or

Albright. He explains that, if a plant goes

ering in the feasibility study, even before

data, accumulated within the mining

down, the information would be able

starting a project. One should start

operations should ideally be included in

to assist with which piece went down,

capturing the data and get systems

one programme that allows people to

where, and where a replacement can

in place so that every design, environ-

use the information, analyse the data

be found.

mental, construction, or other project

and make smarter decisions. Big data

will be able to feed the operation with

starts at the capturing of information

Future of mining

continuous data. Albright adds: “If you

from exploration, in the pre-feasibility

The future of mining is big data – report-

needed, when it is needed,” says

ing on and dashboarding. Big data is the

Incorporating data from various sectors of mining, including mine planning, with other information, is the ideal situation

big trend, allowing companies to predict the performance of the mine. The next step from big data, which is happening already, is spatial data.

This is information gathered from many overlapping photographs, taken by drones or something similar, and meshing the pictures together to create 3D images and/or videos. Albright reckons the next step from big data is creating big systems that can manage big data, from exploration to production.

follow the link http://bit.ly/1LeksWX

In sid e M in in g 0 1 | 2016

33

it & COMMUNICATION

Smart miners

use smart technology A growing number of mining companies around the world are achieving substantially improved productivity and profitability results by using smart technology. South Africa, though, is lagging behind.

This could be a critical failure factor. By Tony Stone

A

34

reasons and necessity for the change can be understood and appreciated by everyone from management down to, typically, a stope worker, where necessary.

To look at a few of the smart technologies available in mineral processing, we find volumetric material analysers, particle size analysers, froth sensors and

S ANY MBA lecturer will tell

Marais, CEO of Stone Three Mining Solu-

bubble sizers, to name a few. But, how

you, measurement is an

tions, says, “Smart technology has an

do these technologies work and why

effective management tool

important role to play in transforming

are they beneficial?

because it provides the

South Africa’s mining industry, from its

information a mine manager needs to

present challenges, to being more prof-

Volumetric material analysers

accurately monitor the performance

itable.” Enhanced productivity, lower

The volumetric material analyser system

of, as in this case, a mine, against

operational costs and improved safety

uses 3D laser scanning technology to

plans, budgets and estimates, in all

are some of the prominent factors driv-

measure volume flow of bulk materials

areas of its operation. In South Africa,

ing the demand for automated equip-

on a conveyor belt in real time, usually

two clear and very real threats to sus-

ment and smart mining technology. But,

after the material has gone through

tainability exist – ore grades dropping

as with all things that require change,

the primary crusher. In some instances,

and commodity prices in a depressed

change must be managed. The most

as in coal processing, this will include

state. Measurement and, through this

difficult of which is to get people to

tool, better management become in-

accept change. The solution, of course,

creasingly necessary to ensure waste is

lies in communication – clear, unam-

minimised and yield is maximised. Louis

biguous communication – so that the

Ins i de Mi n i n g 0 1 | 2 0 1 6

Stockpiling isn't the best idea from a financial perspective

it & COMMUNICATION stockpiles of coal that have been pro-

in detecting equipment wear and dam-

cessed through a dense media sep-

age. It also removes human error from

aration plant, adding yet more costs.

the measurement process and keeps

The primary benefit of this technology

the production process running, without

is to measure throughput and stockpile

any downtime.

quantification, the latter of which is work in progress (WIP).

For accounting purposes, WIP is con-

Froth sensors Froth flotation is a widely used meth-

sidered as a current asset on the bal-

od for precious metals recovery. It

ance sheet. A mine, as with any other

separates the valuable minerals from

business, needs to keep the actual

worthless material, and other minerals,

amount of WIP as low as possible, so as

by inducing the targeted mineral to

to reduce the amount of capital tied up

gather in and on the surface of a froth

in the production process. As a rule, with

layer. A froth sensor is a camera-and-

cash flow so critical, and to increase a

laser-based system used to measure the

return on the capital employed, one

height and velocity of froth in the flota-

needs to minimise the amount of capital

tion cells so as to monitor yield, which

tied up in stock – in this case, a stock-

is determined by the relationship be-

pile. The Japanese, with their ‘Kanban’

tween the frother dosage. This reduces

system, one of the hallmarks of an agile

bubble size by preventing bubble coa-

company, have perfected the science

lescence, and increases bubble stability

of supply and demand management,

and depressant dosage, which is used

not just for themselves, as the producers,

to prevent floatable gangue from en-

but also in understanding their custom-

tering the froth where it dilutes the val-

ers. While miners are tough, they also

uable minerals in the concentrate, and

need to be smart. The volumetric mate-

the air flow rate. By effectively manag-

rial analyser is a crucial tool.

ing these aspects, a significant upward

Particle size analysers What was discovered by DRDGold, in

shift in the grade-recovery curve can be achieved.

Ultimately, though, this translates into

its recovery of gold from old tailings

energy savings, which, through a reduc-

dumps, is that the finer the particles are

tion in concentrate mass pull, presents

that are put through its carbon-in leach

a significant opportunity for savings of

process, the greater the gold yield.

capital and operating expenditure,

This, as an established principle, which

by minimising the smelter capacity

extends to other commodities, makes

requirement.

comminution critical, even in the case of Phoenix Platinum recovering platinum

Bubble sizers

from the International Ferro Metals tail-

A bubble sizer is a portable device for

ings dump near Rustenburg.

acquiring information on the size and

Effective comminution, from primary

distribution of bubbles in flotation cells.

TOP TO BOTTOM The Lynxx particle size analyser stationed on a conveyor belt to monitor the output of a primary crusher

through to secondary comminution,

The bubble sizer equips metallurgical

will increase the number of particles

and process managers with accurate

that will eventually pass through the

data on bubble sizes, bubble distri-

vibrating sieve before going on for

butions, air flux measurements and

further processing. In DRD’s case, a

suspended solids collections. Data

further comminution step was add-

collected by the sensor, including gas

ed – the fine grinding or milling of the

superficial velocity, can also be used

harsh environments where there is other

flotation concentrate.

to diagnose impeller wear and enable

moving equipment, dust and extreme

This gave the site an improvement

flotation process optimisation. The first

weather conditions. “Because we know

in recovery efficiencies of between

industrial bubble sizer was developed

Africa, and understand the financial

16% and 20% – a profitable innovation.

for Anglo Platinum by Stone Three

drivers behind the need to innovate,

Accordingly, measuring the primary

Technology.

we are able to support mines by manu-

and secondary comminution outputs,

Primary and secondary comminution of copper-nickel sulfide ore Froth sensors installed at a platinum processing plant

facturing these technologies to suit very

in real time, using particle size analysers

In summary

to provide statistically representative

These are just four of the deployable

ongoing, responsive service. Our goal is

measurements – to ensure conformity to

smart technologies that can minimise

to play a key role in the modernisation

processing requirements – is crucial. Par-

waste, reduce costs, improve productiv-

of the mining industry, in Africa and

ticle size distribution data is essential to

ity, maximise yield and increase profits.

elsewhere in the world. We have the

plant monitoring and control, especially

Robust and reliable, these technologies

knowledge, experience and track re-

in maintaining process efficiencies and

are specifically designed to operate in

cord to do it,” Marais concludes.

specific requirements, and provide an

In sid e M in in g 0 1 | 2016

35

MINERALS PROCESSING With depressed commodity prices and profit at risk, and the prospect of shareholder dissatisfaction, let alone union problems, miners and mineral processors have only one option available to them – work smarter. By Tony Stone

The evolution of technology and processes

T

ODAY, WITH THE challenges facing the mining and mineral processing industries, the evolution of technology and processes, and

how these impact productivity, must be explored. This really is the crux of the matter and it all boils down to better knowledge and understanding. But, and I will be famous for my ‘buts’ in this arti-

cle, we need to be aware of what’s out there before we can explore and exploit it. The Advanced Mineral Processing Technology, Innovation and Optimisation 2015 conference held in Brisbane, Australia, in October this year discussed a number of topics – some of which we will look at within the South African context.

The grinding challenge

ies that are rapidly becoming more eco-

Careful design to optimise mine processes reduces running costs

nomically viable. The adaptability of the

Ore grades in South Africa have been

mill means it is suitable for a wide variety

declining for some years now. While this

of processes and offers other benefits,

Cape: “Modelling and simulation in min-

has been happening, the world’s popu-

such as minimised energy usage of up

eral processing technology is concerned

lation has been increasing. So, too, has

to 40% to 50% compared with traditional

with the design and optimisation of

the demand for commodities. But, due

ball mills.”

circuits and has become an important

to a global economy in the doldrums

36

types of complex, fine-grained orebod-

method of minimising costs per tonne

and China dipping, with a resultant

Process design

oversupply of commodities, prices have

Andrew Cope of Hatch Goba says, “It is

dropped. To cap it all, ore bodies, too,

only recently that equipment manufac-

Again, and another ‘but’, for the suc-

have been becoming increasingly com-

turers and design engineers have come

cess of modelling and simulation to be

plex, which requires a finer grind size

to recognise the important role that re-

sustained, it is necessary to have a reser-

for maximum mineral grade recovery.

duced energy costs can play in the ulti-

voir of professional skills, and for models

As DRD Gold discovered, by adding

mate profitability of a mining operation

to be available within well-supported

ultra-fine grinding to the process, the

and/or a mineral processing plant. Over

commercial information technology

miner increased its recovery rate quite

and above this, plant design to optimise

products to meet security and business

substantially, and by as much as 25% in

efficiency and productivity has become

continuity requirements.”

some instances. This sets new challenges

critical.” But, this can only be achieved

for grinding technology, with energy ef-

if plant processes are modelled and sim-

ble data, nothing will be achieved. This

ficiency being a major driving force and

ulated using advanced modelling tech-

means doing research, measuring and

yet another challenge to address. Out-

niques during the design phase.

simulating all aspects of the production

otec’s Dirk Slabbert, head: Market Area,

This position was supported by AJ Lynch

process. This is quite simply a manifesta-

sub-Saharan Africa, says, “The High

and RD Morrison when they addressed

tion of the truth in William Edward Dem-

Intensity Grinding (HIG) mill has been

a South African Institute of Mining and

ing’s famous quote, “You can’t manage

designed specifically to manage these

Metallurgy conference in the Western

what you can’t measure.”

Ins i de Mi n i n g 0 1 | 2 0 1 6

through increasing mineral recovery or productivity.”

And, yet another ‘but’, without relia-

MINERALS PROCESSING It begins at the beginning In talking about measurement, knowing what you are dealing with up front is always better for the manner in which you will handle it. The laborious process of sampling, laboratory testing, interpretation and reporting has now been replaced by a rather smart piece of technology, which has its roots in NASA’s Mars Rover programme. The XRD analyser answers the need for rapid mineral identification and quantification. Michael Woodford, CEO of Olympus, says, “In geometallurgical applications, and with the development of two innovative XRD analysers, a field portable model and

FIGURE 1 A typical grinding flow chart showing the positioning of the HIG mill (Source: Outotec)

the bench-top model, these instruments allow operators to rapidly measure phases of importance in minerals processing,

fair and bad, based predominantly on

pyrometallurgical processes, and in ores.

their relative clay and quartz content. It’s

The mineralogical information provided

as easy as point and click.

by these instruments helps to optimise process strategies that can save compa-

Enhancing flotation performance

nies time and money.”

Ari Rantala, senior manager: Automation

He is quite right, and this is what it is all

and Analytics, Outotec, says, “Flotation is

about – accurate measurement and

a key process in concentrator plants. If it

effective decision-making. Let us look

is not operating at the optimum level due

at a case in point. Knowledge of the

to outdated technologies or not utilising

mineralogy of gold ores is important for

the full capacity of modern measurement

optimisation of the beneficiation process.

and control solutions, overall plant per-

Quantities of quartz, talc, calcite and cal-

formance will suffer, causing significant

cium carbonate, fine and swelling clays,

financial implications. Similarly, and in rein-

pyrrhotite, pyrite, graphite and other min-

forcing what Woodford states, changes in

erals can, and do, influence gold recov-

ore deposits may require flowsheets and

eries. The XRD analyser quickly measures

control strategy reconfiguration. Constant

the presence and concentration of these

improvement and optimisation of the

minerals, which allows mill managers to

flotation process can lead to substantial

quickly fine-tune their systems. At one American gold mine in Nevada, a portable XRD

economic and environmental benefits.” In platinum flotation processing, two of

analyser has been used

various smart technol-

to assess the permea-

ogies that should be

bility and absorption

adopted are froth

of leach pad material.

analysers, to meas-

Low permeability and

ure the height and

high absorption of

content and low quartz content) halts percolation and results

New SKF Wireless Machine Condition Sensor provides condition monitoring for large plants, or in hazardous and hard-toreach locations (Source: SKF)

velocity of froth, and

leach liquor (characterised by high swelling clay

The size and distribution of flotation bubbles are extremely important to profitability (Source: Anglo Platinum)

bubble sizers, to measure the size and distribution of bubbles in flotation cells.

While it may be a case of Ripley‘s

indication of a potential machine failure.

Conditions that can cause these vibrations include unbalance, misalignment, looseness of parts, deteriorating rolling element

in slow and incomplete Au leaching. The

Believe It or Not!, these ‘simple’ things

bearing and gear damage. Vibration

XRD analyser was used to measure dry,

have a profound effect on platinum pro-

analysis instruments and systems can help

powdered (<15 mg of 120 μm) leach pad

cessing’s productivity and profitability.

detect serious problems at an early stage,

samples and categorised them to define

allowing personnel to undertake remedial

their likely leaching potential. Samples

Bad vibrations

were easily and quickly grouped as good,

Lastly, there is this little gadget called a

name of the game – automation, meas-

vibration meter that saves lost production,

urement and control, all within a knowl-

time and money, and, in some instances,

edge-driven environment using smart

injury and loss of life. Christoffer Malm,

technology. Is this evolution or something

head: Connectivity Room, SKF, says,

that’s already been out there and we just

“Abnormal vibrations are often the first

haven’t seen it?

ABOVE A Delta Premium XRD analyser being used to test core samples (Source: Olympus)

work in a timely manner.” This, then, is the

In sid e M in in g 0 1 | 2016

37

LATEST EQUIPMENT & TECHNOLOGY

Engineering

genius

A Metso Lokotrack-LT1415 impact crusher in action

Industry is a world of amazing creations – of technology engineered to solve problems and meet the requirements of a diverse range of applications across the realms of human life. We look at just three such creations. By Tony Stone

W

HAT DO A breaker plate,

machine that literally eats mountains. In

a belt plate and a super

this machine, rocks that enter its gaping

screw have in common?

mouth are subject to rock-breaking

You would be forgiven if

shocks given by a rotor fitted with blow

your initial reaction was to say that this is

(as in ‘strike’) bars, which in turn throw

a trick question, but it isn’t. These items,

the rocks against metal surfaces called

components in their own right, are all

breaker plates. In a way, it’s very much

used in materials handling and, in par-

like taking a double punch from a

ticular, mining beneficiation.

heavy-weight boxer – but repeatedly.

Breaker plates

The rotation speed is changeable from 30 m/s to 80 m/s and, of course, the

The first set of jaws brought into focus

faster the rotation, the faster the veloci-

here belongs to the impact crusher, a

ty, and the heavier the impact.

38

I n sid e M in in g 0 1 | 2 0 1 6

LATEST EqUIPMENT & TECHNOLOGY The space between the breaker plates and the blow bars only permits sized material to exit from the crusher. Materials that are larger in dimension

RIGHT A cross section of an impact crusher showing the blow bars mounted on a rotor and the breaker plates with their liners attached (Source: Metso)

remain in the crushing cavity until the correct size is obtained. Then, they

and shreds everything

are discharged. Normally, the crush-

entering its mouth. Natu-

ing cavity is limited by two adjustable

rally, the rough and jag-

breaker plates, which control crushed

ged-edged bits and piec-

product size and capacity. The closer

es that it spits out have to

the breaker plates are to the blow bars,

be transported to loading

the smaller the product size and the

bins, which are used to

lower the capacity through the crusher;

feed SCAW’s melting sys-

the smaller the setting, the faster the

tem, the electric arc fur-

wearing. The further the breaker plates

nace, or to a stockpile.

are from the blow bars, the higher the

Within this configuration, the best

throughput of the crusher and the larg-

means to transport the shredder’s

er the product size will be.

output is to use hinged steel plate

Metso’s latest impact crusher is a big

BELOW Loading scrap metal into a metal shredder (Source: SCAW Metals Group)

conveyors. These conveyor systems

hit. It will chew its way through any

are designed for handling stampings,

problems such as spillage. Steep inclines

mountain. “Performance, profitability

pressed and forged parts, for removing

and curves will be problematic too.

and maintenance of the crushing plant

chips during machining operations, for

To solve this problem, an ingenious

are at the heart of this new crusher,”

die-cast components (zinc and alumi-

Japanese company, now owned by

says Vincent Schmitt, product manager

num), for transporting rounds (coins and

Bridgestone, invented the pipe con-

for NP Series impact crushers.

extruded parts), for pellets,

Belt plates

veyor – a normal conveyor belt

screws, rivets, and other

that is shaped by rollers

fasteners, as well as

into a pipe for the du-

As metallurgical engineer Steve van

scrap waste, other

Wyk, executive head of operations,

mass parts, and

SCAW Metals Group, explains, “Steel

for granular bulk

ditional conveyor

is 100% recyclable and it is indeed the

material. Thus, a

system or a pipe

most recycled material globally. Every

belt plate is just

conveyor, a prob-

new steel product contains recycled

one segment

lem occurs when

steel and, in some countries, the recy-

of the conveyor

there is a tear or

cling rate can reach 85%. We produce

belt. Each belt

in excess of half a million tonnes of liq-

plate, made of

uid steel each year using recycled steel

highly resistant cold-

scrap and directly reduced iron from

rolled steel, is hinged

rotary kilns.

together with another, and

ration of the trip. But, whether it is a tra-

break in the conveyor belt. Effecting a repair using the traditional vulcanising method will be time-consuming and costly,

so on, to form the entire belt. In South

and it would be best not to forget the

arrive at SCAW’s premises in Germis-

Africa, this type of conveyor is also

impact on production.

ton, south-east of Johannesburg. The

known as a slat band conveyor. Neil

company purchases both processed

Muller, CEO, Conveyco, a local man-

company, Minet Lacing Technology,

and unprocessed scrap and operates

ufacturer of slat band conveyors, says,

developed the Super-Screw, a flexible

the largest scrap shredder in Africa.

“We provide almost every conceivable

rubber splice with steel inserts for joining

The shredder itself is a high-capacity,

application found within the South

conveyor belts, as an alternative to

rugged-design machine with a power-

African materials handling industry.

traditional vulcanising.

ful set of hard-wearing jaws that cuts

What’s more, every piece of equipment

Every day, truckloads of scrap metal

A section of a belt plate conveyor (Source: National Element)

To solve this problem, an innovative

The screws are self-tapping, spreading

we commission is manufactured in our

the carcass threads without cutting

Cape Town factory.” That being said,

them. No heavy or sophisticated tool-

perhaps we should buy South African.

ing is required to do the installation

Super-Screws

other than a cutter and an electric drill.

The Super-Screw fastener can also be

While the Super-Screw itself is not a

used for lateral and/or longitudinal belt

jaw-like device, it does have some-

rip repairs.

thing to do with the output of a jaw-like

Three different stories, but each one a

device. Grinding mills that produce a

fascinating reflection of human ingenui-

powder-like material, such as cement,

ty. The thread that permeates these sto-

pulverised coal or phosphate, which,

ries is this: if you have a problem, give

if transported over any distance via a

it to an engineer. He or she will surprise

traditional conveyor system, will cause

you with the solution.

In sid e M in in g 0 1 | 2016

39

LATEST EQUIPMENT & TECHNOLOGY

Sensing what

humans can’t There are a multitude of sensors and monitoring equipment available on the market, each as valuable as the next. However, hazardous-environment sensors can mean the difference between life and death. Mientjie Kleinhans looks at how these sensors work.

E

verybody knows the importance of sensors detecting the presence of gas before it endangers the lives of humans,

This sensor has a localised information display, making it simple to read, and it can also accommodate other sensors with analogue outputs

presence of the target toxic gas reacts with the chemical mixture contained in the sensor cell producing an electrical

the environment or assets, such as in

output proportional to concentration

a processing plant. How the sensors

of gas. Specialised manufacturers offer

work may be lesser-known. It is inter-

photo-acoustic-based sensors using

esting to find that technologies used

light and sound detection principles

in gas, flame and specialised lead-de-

for detecting toxic gases. Metal oxide

tection sensors vary according to the

semiconductor detection technology

target gas.

is also used to detect hydrogen sulfide, which is a toxic gas commonly found

Combustible gases can be detected using three different technologies,

in the industry and specifically in the oil

each having a specific attribute in

and gas sector.

its application – explains Robby Taitz, fixed gas and flame detection product

Flame-detection sensors

manager at the MSA Group. He adds

Flame-detection sensors are used

that these technologies are commonly

as early warning for flame triggering

known as catalytic sensing, infra-red

avoidance actions to prevent esca-

(IR) detection and photo-ionisation

lation to a disastrous situation. The

detection. Each of these technologies

technologies commonly employed for

has specific role attributes.

this purpose are UV or IR, or a combi-

“The catalytic sensor is the lower-cost

nation of both.

option for the detection of non-vol-

“Leak detection of gas is a special-

atile combustible gases where there

ised technology area, where the leak-

is sufficient presence of oxygen. IR

ing gas, when it is under pressure, emits

technology finds its niche where a

using sensors based on different tech-

ultra-sonic sound. This ultrasonic sound

dirty environment may exist, where

nologies, according to Taitz. The most

is detected by a sophisticated micro-

there are products in the air that could

common detection method is using

phone circuit, which has the capability

contaminate a catalytic sensor; or where there is a need for a long-life device with a quick response to specific combustible gasses; and, also, where the need exists to have a sensor that performs well in no- or low-oxygen environments,” says Taitz. Photo-ionisation detection technology lends itself to detecting combustible or volatile organic compounds that are too volatile for detection by catalytic or IR sensors. Many other industrial gases are toxic and need to be detected

40

an electrochemical sensor, where the

Ins i de Mi n i n g 0 1 | 2 0 1 6

to eliminate noise and focus on the

“The collected data is used as an early warning system to detect a potential dangerous situation, malfunctions, and for corrective action.”

ultrasonic sound and not be affected or triggered by false conditions,” says Taitz. Jaco du Plessis, research and development manager at Booyco Electronics, adds that gas sensors that use electrochemical, catalytic and IR technologies are used in conjunction with an electronic circuit. “This enables the result to be produced on a digital platform, which facilitates visual access to gas-level information in the field, using Scada,” says Du Plessis.

LATEST EqUIPMENT & TECHNOLOGY “Leak detection technology is highly specialised, isolating ultrasonic frequencies emitted by leaking gas from the surrounding noise.” Robby Taitz Sensor communication

A low-maintenance unit without any buttons is operated using an innovative tap sensor, ensuring that the instrument remains watertight to a disaster level,” says Taitz. Furthermore, the data collected from a personal device can be used to determine the longtime exposure (LTE) of persons to specific gases, explains Du Plessis.

“Data from multiple devices used in

Where a gas-detection device is car-

the same area can be analysed to

ried on a person, the data accumu-

determine if that area is prone to high

lated from the sensors can be downloaded via a wireless communication platform to a database, according to

Robby Taitz which is configured to identify prede-

Du Plessis. “A second option is a fixed

termined risks and put controls in place

installed sensor that is in constant com-

to eliminate these risks. “Sensors have

munication with a Scada via a wired

a lifespan of about two years. This

communication bus. This bus can be

can, however, be reduced through

fibre- or copper-based.” Depending

constant exposure to high gas levels.

on the interface of the sensor, it can

The sensor may become less sensitive

communicate with devices from any

over time because of this; but, with the

underground or remote environment,

use of an efficient management sys-

given the correct infrastructure.

tem, this risk can be eliminated,” says Du Plessis.

Data collection

Different sensors come in different siz-

“The collected data is used as an early

es, and are energised differently. Some

warning system to detect a potential

sensors, like personal devices, use a

dangerous situation, malfunctions, and

battery, while fixed units are powered

for corrective action. In a worst case

directly from a fixed energy source.

scenario, a shutdown will take place to

Some sensors are tamper-proof, while

prevent an escalation of the problem

others are not immune to malicious tampering. Choosing the sensor will depend on the applications required.

gas levels, for instance. “The fixed sensor facilitates a trend of gathering data over a preselected period of time.

This allows the determination of what the environment does at certain times or in certain situations – providing valuable information. An example would be the efficiency of a ventilation system in an underground environment,” explains Taitz.

“Data from multiple devices used in the same area can be analysed to determine whether the area is prone to high gas levels.”

Jaco du Plessis

Benefits Du Plessis explains that, because sensors allow for the accurate detection and measurement of gas, the infor-

Interchangeable smart sensors eliminate the need for reconfiguration

mation can be used to determine specific required outcomes based on the application in which the sensor is used. He also explains that sensors generally form part of a larger system,

In sid e M in in g 0 1 | 2016

41

www.polypipe.com/mining

42

Ins i de Mi n i n g 0 1 | 2 0 1 6

LATEST EqUIPMENT & TECHNOLOGY

Quick and efficient solution

W

hat used to be a tempo-

being conducted through the CSIR on

seven hours, a cold splice takes over

rary alternative to conven-

various splice types and on wider belts

eight hours (including curing) and the

tional hot and cold splicing

(500 mm). We expect to achieve even

Super-Screw takes less than one hour,”

has proved to be totally

better results, which will be published

says Scott.

reliable as a permanent splice for con-

soon,” says Donovan Scott, divisional

veyor belt repairs. The Super-Screw from

manager: Bulk Materials Handling, BMG.

BMG also replaces hazardous solvents,

He adds: “Field tests indicate that the

like trichloroethylene. The high-strength

splicing system is the quickest method

splicing system is a flexible rubber splice

to repair a conveyor belt in any emer-

using self-tapping screws that enable the

gency situation, significantly reducing

belt fastener system to be installed re-

downtime. The mechanical joining tech-

gardless of the configuration of the con-

nique is easy to complete, without the

veyor belt, and irrespective of access

need for a skilled operator and heavy,

and weather conditions.

costly equipment. This system, with a

To stay within the mining trend of

The Super-Screw belt fastener system screws onto a conveyor belt for efficient repair in all conditions

high tensile strength, has proved to be

avoiding the use of hazardous substanc-

a suitable alternative to conventional

es, the splicing system replaces hazard-

splicing methods.” In some cases, the

ous solvents. “BMG, in conjunction with

splice system exceeded the tensile rat-

the SABS, has used various belt classes

ing of hot and cold splice samples of the

and widths to test the Super-Screw in

same class rating. “Trials, using the same

different applications over the last three

belt width of 600 mm, also demonstrate

years. Further tension tests are currently

that a conventional hot splice takes

In sid e M in in g 0 1 | 2016

43

PART OF THE MINING PROCESS BMG doesn’t merely deliver superior quality engineering components to the mining industry. We know that to truly deliver – to truly provide optimum service for our customers’ needs–our solutions need to be accompanied by both insight and foresight.

Insight in to the technical requirements of your operating process as well as your budgetary parameters, gained through personal, direct and thorough consultation. Foresight into how our technical expertise, on-site maintenance plans, custom design capabilities and training can all be applied to further maximize your production efficiencies.

It is this commitment that has driven BMG to become a powerful industry leader. Parts for every process. Part of yours.

BEARINGS • SEALS • POWER TRANSMISSION • DRIVES & MOTORS • MATERIALS HANDLING • FASTENERS & TOOLS HYDRAULICS • PNEUMATICS • FILTRATION • LUBRICATION • VALVES • TECHNICAL RESOURCES • FIELD SERVICES

BEE 343

In sid e M in in g 0 1 | 2016

BMG-SJ19112015

For more information, contact your nearest BMG Branch

cover story

YOU CANNOT MANAGE WHAT YOU CANNOT MEASURE WHO WE ARE

DIESEL-PARTICLE-MASS-ANALYZER DPM

DISPRO TECH SAâ&#x20AC;&#x2122;s core business function is in measuring, verifying, reporting and dealing with all vehicle and equipment type emissions and provides both on-site and roadside emissions testing assistance.

DISPRO TECH SA

Recognises the goal of climate change mitigation in the South African Air Quality Management Plan and has come together with Industries in efforts to reduce Green House Gases and other polluting emissions, such as particulate matter from diesel engines emitted from heavy machinery.

DISPRO TECH SA

Is a leading South African business that addresses environmental and industry needs nationally.

INFRALYT ELD

OPACILYT 1030

CONTACT US

email: info@disprotech.co.za email: sales@disprotech.co.za mobile: +27 (0) 81 319 0877 BEFORE & AFTER

www.disprotech.co.za 44

Ins i de Mi n i n g 0 1 | 2 0 1 6

HAND-HELD DEVICE

LATEST EqUIPMENT & TECHNOLOGY

Measuring diesel particulate matter T

HIS MEANS THAT clients can now effortlessly follow best interna-

• see an increase in productivity due to uptime of machinery availability

Diesel particulate matter is well known for its harmful effects on human health and the environment.

Mines are now able to detect, quantify, verify and certify DPM 2.5, utilising internationally accredited, EPA approved and Internationally approved US ASTM as well as European standards.

Scope of testing The scope of testing aims to investigate

tional practice as prescribed

•a reduction in harmful exhaust matter

and determine the state of the engine

by the Mine Health and Safety

• an engine diagnostics tool pinpointing

health, as well as efficacy and impact

Council and the Chamber of Mines po-

sition paper on diesel particular matter.

In addition to occupational health and

the cause of the engine problem • a reduction in general equipment engine maintenance

environmental benefits, mines will now

•reduced fuel consumption

be able to comply with the National En-

In line with global information technology,

vironmental Management act (NEMA)

the company also offers accessibility to

as well as the Air Quality Act, 2004 (Act

accumulated data online with a dedicat-

No. 39 of 2004) and National Amospheric Emission Reporting Regulations, that were promulgated in April 2015, with the range of both Mirenco (MDEP) Technology as well as the world first infrared exhaust gas analyser technology from Saxon Junkalor.

“These analysers lead the industry with their ability to measure diesel particulate matter directly from an exhaust stack,” says Martin Titus, marketing director at Dispro Tech. Besides detecting and measuring diesel particulate mass, these

ed log in username and password. The

“Mirenco and Saxon analysers lead the industry with their ability to measure diesel particulate matter directly from an exhaust stack.”

of various fuels and exhaust stacks after treatment systems on: • fuel consumption to determine the source of bad emissions • occupational health and safety to test for the six most common gaseous emissions like: HC, O2, CO2, CO, NO and

NO2. Soon to be added SO2 is in the final stage of development.

• DPM 2.5 and DPM 1.0 (diesel particulate mass – mg/m3) • DPM (opacity in K or percentage) • MDEP (Mirenco Diesel Evaluation Procedure – combustion efficiency that include DPM, HC, O2, CO2, CO and NOx).

Range of products There are four models in the Saxon range: Junkalor DPM1.0, Junkalor ELD 6 Gas Analyser, Junkalor Opacilyt 1030 Smoke

analysers lead the industry with their

combustion reports provide a calculated

Meter and MDEP (Mirenco Diesel Evalua-

ability to measure and record diesel par-

and accurate account of litres of fuel lost

tion Procedure).

ticulate matter, mass and GHG directly

per year for each engine, recommenda-

Each one of the analysers has different

from an engine that is burning fuel, and

tions for engines requiring combustion loss

features to suit various needs. The com-

detect possible trouble spots for targeted

correction, and a reporting tool on emis-

pany sells, rents and maintains equip-

and predictive maintenance repairs. The

sion levels. Titus says that engines receiv-

ment, and also sells spares and accesso-

system also keeps an electronic GHG

ing combustion-loss correction average

ries to customers.

inventory for clients to acces.

30% longer life between overhauls, and

According to Titus, some of the benefits

that combustion diagnostic testing pro-

of the analysed exhaust gas emissions is

vides an average of 25% less downtime

a recommendation pinpointing potential

by avoiding unplanned engine repairs

engine problems. Maintenance techni-

and services. “The combustion history files

cians can now do the following:

provide fleet management with informa-

• carry out predicitive and preventa-

tion for choosing engines and equipment

tive maintenance, leading to fewer

that provide less cost and problems over

surprise breakdowns

their life cycle,” says Titus.

www.disprotech.co.za martin@disprotech.co.za / info@disprotech.co.za

In sid e M in in g 0 1 | 2016

45

cover story

Muleby System Tanks (MST) installed for CMC South Africa/PG Mavundla Joint Venture, in Springs Gauteng for a new acid mine drainage plant.

Concrete reservoirs for secure and clean water resources

Individual concrete panels are each assembled onto the cast-in-situ reinforced concrete slab.

The system is post-tensioned using horizontal circumferential mono strands to keep joints compressed.

Durable and designed to last.

In the mining industry advanced water storage solutions are of vital importance to meet wastewater and clean water delivery challenges. The tough and versatile Muleby System Tank from Aquadam benefits water infrastructure sectors in the mining industry, industrial and renewable energy projects. This is an effective storage solution available in a wide range of customdesigned volumes of 175,000 liters to almost 6 million liters to save water for the ever-growing water demand.

Engineered Designed according to: Manholes, anchorages etc. are cast as required, and the system can be closed with a pre-cast or cast-in-situ roof.

• EUROCODE 2: Design of concrete structures - Part 3 “Liquid retaining and containment structures”,

• The South African Standard Code of Practice - Structural use of Concrete: SABS 0100-1 Edition 2.2 (2000),

• The British Standard Code of Practice for - Design of Concrete Structures for retaining Aqueous Liquids: BS 8007:1987,

• SABS 01060-1989: Design loading for water retaining reservoirs, as amended 1990, 1991, 1993.

Quote referral code “Inside Mining” in your enquiry.

B-BBEE Level 2 contributor

Contact 086 100 1010 • www.aquadam.co.za For Mining & Industrial Applications contact:

Willie Palm Tel: 012 810 0940 | E-mail: sales1@aquadam.co.za

46

Ins i de Mi n i n g 0 1 | 2 0 1 6

Link to Aquadam watertight solutions or AquadamCoZa/Aquadam solutions

LATEST EqUIPMENT & TECHNOLOGY

Containing a

toxic threat

A new AMD treatment plant and pump station is currently being developed in the Eastern Basin, at the Grootvlei Mine No 3 shaft, in Springs. The acid mine water will be treated before being discharged back into Gauteng’s rivers.

T

HE PROJECT IS scheduled to be fully operational by the first quarter of 2016 and the facility’s operational target is to neutralise about

84 MLD (million litres per day) of AMD (acid mine drainage).

AMD is the flow or seepage of con-

taminated water from old mining areas into groundwater. As a result of gold mining operations in South Africa’s Witwatersrand Basin over the last century, underground voids have been created and have filled with acid mine water.

The contaminated water has had a dramatic impact on groundwater conditions and poses a threat to surrounding residential and agricultural communities, who rely on the rivers as a source of po-

Springs for the new plant. Each MST can hold up to 550 Kℓ of water, where three of the reservoirs have already been commissioned with water. “The MST is a superior, cylindrical concrete reservoir,” says Willie Palm, sales consultant at Aquadam. In terms of the AMD plant in Springs: “There is no alternative but to recommend our best-engineered reservoir. The MST is probably the most advanced reservoir solution on the market to assist in the containment of this possibly disastrous threat to communities.

“The warranted design provides customers with benefits, such as factory-controlled quality, fast assembly and a maintenance-free tank. In accordance with the requirements for the highest

table water and irrigation.

classification of water tightness of the

Aquadam – part of a cleaner solution

Part 3 – the MST is suitable for both fresh-

Aquadam was subcontracted by the CMC South Africa-PG Mavundla joint venture to construct concrete reservoirs as limestone and quicklime dosage tanks for the Trans-Caledon Tunnel Authority, the state-owned entity responsible for the AMD plant. Six Muleby System Tanks (MSTs), with a diameter of 12.10 m by 5 m high, have been constructed in

European Standard – Eurocode 2, water storage and wastewater treatment,” says Palm.

Creating a watertight structure The precast concrete MST is a construction product produced by casting concrete in a reusable mould or ‘form’, which is then cured in a controlled envi-

site and lifted into place. Individual panels vary from three to seven metres in height and are precisely fabricated to fit with neighbouring panels on assembly of a cast-in-situ bottom slab.

Waterproof mortar is used throughout in the construction of the reservoir wall to seal the vertical joints between the panels. In order to pre-stress the structure against the considerable force that is exerted by such a large volume of water, Aquadam applies a construction technique known as post-tensioning to keep joints compressed. The circumference of the completed cylindrical structure is ringed with a series of tough metal strands and each of these are individually tightened together to create a perfect seal.

Aquadam utilises mechanised procedures for quicker and non-labour-intensive construction, which, in turn, makes the MST a very cost-effective choice in reducing time spent on-site. The MST can be installed virtually anywhere: sunken, partially buried or at ground level. Sizes range in capacities from 174 m³ (174 000 ℓ) up to 5715 m³ (5 715 000 ℓ). Aquadam can assist in the implementation of innovative water storage solutions to secure water resources and improve wastewater management.

Muleby System Tank applications Aeration Anaerobic digesters (biogas) Clarifiers Digestion Fermentation Filtration tanks Loose storage tanks (salt, sand, chipping, etc.)

Rainwater harvesting Sedimentation Sprinkler tanks for fire protection Stormwater retention basins Water and sanitation

ronment, transported to the construction

www.aquadam.co.za

In sid e M in in g 0 1 | 2016

47

We are a specialist engineering group focused on fast-tracked design and construction of minerals processing plants on a fixed price basis (EPC/LSTK).

We excel in delivering projects in remote locations and developing countries.

OUR COMMODITY PORTFOLIO INCLUDES: Chromite & Ferrochrome - Recovery Plants Coal - Handling & Preparation (Wash) Plants Copper, Lead, Zinc, Tin & Tungsten Pre-Concentration & Beneficiation Plants Diamonds & Gems -Extraction & Recovery Plants Gold & Silver - Recovery Plants Iron Ore - Beneficiation Plants Mineral Sands - Wet & Dry Plants Platinum - Flotation Plants Tin & Tungsten - Recovery Plants

Email: enquiries@consulmet.com

CONNECT NOW

+27 (0)11 608 0396 | +27 10 001 8550 | +27 (0) 11 553 6960 | +27 (0)21 001 3541/45

www.consulmet.com

LATEST EqUIPMENT & TECHNOLOGY

Scaleability, availability, reliability

T

Focusing on the fast-tracked design and construction of minerals processing plants on a fixed price basis is one of the methods companies can use to help reduce costs in a mining sector that remains under pressure. he mining environment has

Nevertheless, Lahee says he remains

A promising future

placed engineering companies

optimistic regarding Consulmet’s future.

Lahee encouragingly indicates that

in a gruelling positon, with a num-

By using methods such as zero esca-

he expects the markets to correct

ber of companies shifting focus to

lation on standard plant quotes over

themselves sometime in the near fu-

infrastructure and construction in a bid

the last two years, simplifying designs,

ture. “The future is very exciting, and

to remain above water. However, there

expediting processes and the installa-

process engineering skills are going to

are some specialist engineering groups

tion of cheaper equipment only up to a

be in very short supply.” The skills and

that opted to stick with mining opera-

certain point – to avoid quality suffering

values around process engineering are

tions. Consulmet is one of these groups.

– the company has, indeed, ‘bitten the

at the core of Consulmet’s values and

Derek Lahee, managing director of the

bullet’. In the same breath, Lahee does

ambitions and, although Lahee says he

process engineering firm, says it wasn’t

warn that there is a fine line between

sometimes fears this might be part of a

an easy feat to remain profitable in these difficult times. “We tightened up our focus on our core business, which is modular diamond plants.

“This was done by targeting key areas such as better quality control, industry-leading delivery schedules and being at the forefront of technology implementation,” says Lahee. However, he does admit that some diversification had to take place in order to come through in the tough, prevailing market, “Some years ago, we began diversifying into infrastructure (electrical and civil).

With South Africa possibly headed towards a critical shortage of engineers, growth and quality execution are imperative in the light of Africa’s potential long-term growth

The key here was, again, to focus on

dying breed, he reiterates that the quality and quick turnaround time of deliverables the company offers will keep it in the game. With the predicted activity in the sector across the continent, it will be exciting to see what the process engineers in the region will do to remain competitive. “We are ideal for the mid-tier companies that have to get mines up and running

projects that we knew would be per-

cutting costs and sacrificing quality. “I

as quickly as possible to ensure cash

fectly complemented by our skill set.”

think our industry is at that point – there

flow, as well as those who do not have

is a graveyard of cheap process equip-

the large administration staff necessary

ment out there due to poor design and

to manage more systems-oriented com-

About the current state of the minerals

poor quality that has ultimately led to

panies,” Lahee concludes.

and metals projects environment, La-

the failure of projects. The process engi-

hee, who has been in the industry for 27

neering business is a complex business,

years, says, “It is, by far, the worst situ-

and this aspect is often overlooked in

ation I have seen in a very long time.”

the drive to save costs.”

Current affairs

Derek Lahee, managing director of Consulmet

In sid e M in in g 0 1 | 2016

49

cover story

Celebrating

special risk fire protection

25 Years 1990 to 2015

The Akron Brass Severe-DutyTM manual and electric/hydraulic water canons have been designed for mining washbays and watercart industries, and will withstand continuous operation with poor quality water in normal everyda ay conditions. everyday

REMOTE WATER CANONS

SEMI-AUTOMATIC & AUTOMATIC WATER CANONS ®

Sev Severe Duty Monitor Continuous use app applications, vehicle washdown, dust sup suppression & fire fighting.

290 2900 L/min @ 5 - 14 bar

MANUAL M ANUA WATER CANONS

SEVERE-DUTY 50

Ins i de Mi n i n g 0 1 |

+27 (0) 861 111 544 Mike: +27 (0) 83 251 9346 2016 mgf@dosetech.co.za • www.dosetech.co.za

LATEST EqUIPMENT & TECHNOLOGY

Severe-duty water

cannons for mines Akron severe-duty water cannons have been specifically developed to continuously work in harsh mining, rail, road tanker and industrial wash-down or cleaning applications, without adding more challenges to maintenance requirements.

E

Stationary installation with remote operation

or programmed for a given wash-down cycle – reducing vehicle wash-down times from hours to

ight years ago, Akron answered

case, every minute a mining vehicle, rail

minutes. “Akron is

the mining industry’s call to pro-

cart or road tanker remains in the wash

possibly the largest

duce a reliable water cannon.

bay or out of service can be used in this

manufacturer of

Previously, the only option for

calculation,” says Feldon. He explains

water cannons and

water cannons was typical fire protec-

that the water available for these types

handheld nozzles in

tion equipment, which was never pro-

of applications is normally of a poor

the world, with vast

duced with the view of daily and contin-

quality, untreated and recycled, possi-

experience in the min-

uous use, using poor-quality water and

bly even slightly abrasive, which reduces

ing, industrial, and mu-

operating in dusty, harsh environments.

Inevitably, the fire protection water cannons or monitors, as they are known, would fail or fall apart (wear out), creating additional maintenance headaches for the facility operation crew, plus huge expenses due to the delayed turnaround of costly mining equipment.

“The mining industry breathed a collective sigh of relief with the launch of purpose-designed Akron severe-duty water cannons. Equipment is finally available on the market to get the re-

“The mining industry breathed a collective sigh of relief with the launch of purposedesigned Akron severe-duty water cannons.”

nicipal firefighting and fire protection industries. The company recently appointed DoseTech of Cape Town as its sole representative and service centre for sub-Sahara – Africa,” says Feldon.

DoseTech has been supplying Akron products for the past five years and offers a refurbishment service on all old Akron monitors from the accredited service centre. “The extension of products into the severe-duty range came from user experience over many years

quired cleaning, wash-down and dust

the operational life of fire protection

and Akron was willing to experiment

suppression done efficiently and reliably.

water cannons. The Akron severe-duty

and develop to meet customer needs,”

There is also a five-year warranty on the

manual and remote-operated water

says Feldon.

manual units and a two-year one on the

cannons have been designed for these

automatic,” says Mike Feldon, manag-

harsh conditions with stainless steel

used for many applications outside of

ing director, DoseTech.

or heavy-duty brass waterways and

firefighting, including tank washing and

heavy-duty joints suitable for continuous

crowd control. Firefighting remains the

vibration. The cannons can either be

core business of Akron and the com-

“As always, the major benefit of sup-

mounted stationary or fitted to heavy

pany manufactures a comprehensive

plying purpose-designed and reliable

vehicles, for applications such as dust

range of products to handle water and

equipment is the payback period, which

suppression. The severe-duty water

foam, as well as hand tools, scene light-

is immediately implemented. In this

cannons can be operated manually

ing, flow meters and vehicle wiring multi-

Severe payback

Water cannons are now generally

plexing programmable systems.

www.dosetech.co.za

follow the link Slimes dam

http://bit.ly/1Re2Y0u

In sid e M in in g 0 1 | 2016

51

cover story

PRESENTING THE 2016 KEYNOTE SPEAKERS

TENDAI BITI

DR. HARRY G. BROADMAN

MAKHTAR DIOP

Former Finance Minister Government of Zimbabwe

Director, Council on Global Enterprise and Emerging Markets and Senior Fellow, Foreign Policy Institute Johns Hopkins University

Vice President, Africa World Bank Group

ROBERT FRIEDLAND

DR. ANIL K. GUPTA

NAMRATA THAPAR

Executive Chairman and Founder Ivanhoe Mines Ltd.

Michael Dingman Chair in Global Strategy & Entrepreneurship Smith School of Business, The University of Maryland

Global Head of Mining International Finance Corporation

REGISTER TODAY! Register before 23 Jan 2016 and SAVE AN ADDITIONAL ÂŁ100 on your new individual delegate registration. Mention the required offer code PAIM3 for discount.

52

Ins i de Mi n i n g 0 1 | 2 0 1 6

www. m i ni ngi ndab a .c o m

EVENTS

A global drawcard At the upcoming 2016 Investing in African Mining Indaba, taking place from 8 to 11 February in Cape Town, investors, financiers, governments, mining executives and other industry stakeholders will gather for one week of unparalleled insight and dealmaking of pan-African mining opportunities.

By Jonathan Moore

F

ing Indaba has presided as the

Changing dynamics do not alter mineral wealth

convener of global players in the

As the demographics and dynamics

industry to provide the platform

of Africa continue to change, there

or more than 20 years, the Min-

• $400 billion to be spent on South Africa’s government-proposed infrastructure programme.

that channels billions of dollars in capi-

remains one constant – Africa’s mineral

talising the African mining value chain.

wealth. The continent currently holds

Expanded platform for uncovering investment opportunities.

The acceleration of the mining industry

30% of the world’s natural resources; it

At the 2016 Mining Indaba, we intend to

on the continent has not only served as

produces more than 60 minerals and is a

leverage the platform of bringing inves-

a source of revenue and employment

major producer of gold, platinum group

tors, mining companies and government

but has also provided a gateway for

metals, diamonds, uranium, manganese,

together to explore what the sector is

investors to see all of Africa’s potential.

nickel, bauxite, cobalt and chromium.

doing to strengthen its position in the

Africa, once viewed as a high-risk and

Mining will continue to be a major reve-

current environment and how it is devel-

uncertain investment destination, is now

nue producer for the continent – it is ex-

oping an investment strategy to better

considered the emerging-market story

pected that mining will bring $30 billion

position itself for when demand for com-

of the next generation.

per year for the next 20 years.

modities returns. The current market offers

Today’s global investors are looking

opportunities for organisations to take a

seeing investment opportunities across

Much optimism for the resurgence of African mining

the spectrum, from infrastructure to

The trend lines on Africa’s numbers head

erational efficiencies, to evaluate how

telecommunications, consumer goods

toward the return of a stronger and more

best to make investments without being

manufacturing and more. FDI flows into

sustainable mining sector. Important facts

directly exposed to the risks associated

developing economies are projected

and figures fuelling Africa’s optimism:

with investing in the mining sector, and

to reach $850 billion by 2016, from $681

• 11 of the world’s 20 fastest-growing

to identify the critical partnerships for de-

billion in 2014. Two-thirds of executives

economies through 2017 in Africa

velopment and acceptance of mining in

at Africa through a different lens and

expect flows into Africa to grow – the highest optimism of any region, according to Mail & Guardian.

• 17 African countries ahead of India on the World Bank’s Ease of Doing Business Index

hard look at how they conduct business and what they can do to improve op-

the years to come.

On the agenda

Other African industries are capturing

• 11 of 18 African countries measured

At the 2016 Mining Indaba, you will have

the attention of global investors, as they

have been improving overall policy

the opportunity to contribute to these dis-

are growing at a steady pace because

attractiveness – Mauritania and Namib-

cussions, take advantage of the growth

of the growing demands and output of

ia, in particular

opportunities and take the lead in this

the continent’s population of over a bil-

• 36 African countries are ahead of

increasingly competitive market. The an-

lion people, which is also comprised of a

Russia on Transparency International’s

nual indaba is “where the world connects

significant emerging middle class.

Corruption Perception Index

with African mining.”

In sid e M in in g 0 1 | 2016

53

EVENTS

And the winner is…

Every year, Bentley Systems commemorates the best projects at the Year in Infrastructure conference. 2015 saw another spectacular event held in London, UK. The finalists from various industries were introduced and the winners were announced at the gala dinner.

All the Bentley award winners.

T

HREE FINALISTS from 18 different

been chosen from over 360 submissions

managed to design a plant with the least

industries, media from around

from 66 countries. One of the categories

capital cost, yet satisfying plant produc-

the world, industry specialists

was ‘Innovation

and Bentley Systems represent-

in Mining’ and

atives all gathered to celebrate magnif-

the three final-

icent projects at the Be Inspired Awards

ist companies

ceremony. All the finalists’ projects were

were Tetra Tech

designed using Bentley Systems

Proteus, CCTEG

software. Ten independent

Beijing Huayu

panels of jurors, special-

Engineering, and

ists from their industries,

Changsha Design

selected 18 winners from

and Research

54 project finalists.

Institute of Non-

The finalists had

ferrous Metallur-

“Using the appropriate software, we were able to get cost estimates, create 3D models, images and animations of the design work, and 2D drawings.” Stewart Phillis

54

Ins i de Mi n i n g 0 1 | 2 0 1 6

ery targets. Using Bentley software, the company made appropriate modifications to 3D model templates from prior projects to cost-effectively produce the optimised plant layout, reduce civil construction costs,

gy. The competition was tough and it

and reduce concrete, steel, piping and

was quite a challenge for the judges to

electrical capital costs. Some of the chal-

choose one winner.

lenges that the company had to deal

Industry winner

Stewart Phillis, director and CEO, Tetra Tech Proteus

tion and recov-

with included: •sites were located in remote locations

The winner in the mining category was

•limited access to the sites

Tetra Tech Proteus with the project

•extreme temperatures

Kvanefjeld Rare Earth: Uranium Project,

•work in a fragile environment

which has been taking place in Narsarm-

•traditional use and land ownership

ijit, Greenland. What made this project

• the effects of ice and the impact of

extraordinary was that the company

building on frozen ground.

EVENTS Feasibility study During the feasibility study, it was determined that the Greenland Minerals and Energy Project needed to develop the mine site, concentrator, refinery, an access road and a tailings storage facility, all with an estimated budget of $1.36 billion.

“With the Bentley software, we were able to get cost estimates,

“Our plant layout was able to be easily adjusted, reducing the need for cut-and-fill works by five million cubic metres, which resulted in cost savings of $100 million in earthworks.”

create 3D models, images and animations of the design work, and 2D drawings,” says Stewart Phillis, director and CEO, Tetra Tech Proteus. “We also had fantastic success in identifying ways to reduce the earthworks. Our plant layout was able to be easily adjusted, reducing the need for cut-and-fill works by five million cubic metres, which resulted in cost savings of $100 million in earthworks.” He adds that the story doesn’t end there: “We recently were able to produce an option study with one of our

designers, over a two-day period, to test other options of saving costs. This resulted in saving an additional $100 million. ”The design project took Tetra Tech Proteus 17 weeks to design, with an average of two designers per week for four months. At the end of the design project, the company managed savings of $100 million from the design review, reduced the project delivery time, and earned community acceptance. The community members were impressed, as they were able to see that the project would have a minimum visual impact on their land, a low social impact and bring economic benefits to them.

The proposed development of the Kvanefjeld Rare Earth and Uranium Project in South Greenland features a mine, concentrator, refinery, port, accommodation village, and infrastructure In sid e M in in g 0 1 | 2016

55

ALG Relining and Rubber Lining CC

Members and Staff of ALG Relining and Rubber Lining have extensive experience in various types of steel liners, rubber liners and rubber lining.

ALG Relining have experience in the engineering field and has current undertakings of extensive work at existing mines both nationally and internationally.

ALG Relining is a specialist outsource company providing services such as relining of steel lined mills, relining of rubber lined mills, rubber lining of plant equipment maintenance and consultation of milling equipment to the mining and related industries.

Suppliers; ·

Multotec Limited

·

Tega Industries Limited

·

Metso

·

Linatex

·

SRP

·

Rubber Resources

·

Bond Tech Rubber

ALG Relining & Rubber Lining CC No. 35 Zondereind Street Harmony, Virginia Free State, South Africa 9430

Tel: +27 572 171 083 Fax: +27 865 656 665 Email: sales@algrelining.co.za Web Site: www.algrelining.co.za

EVENTS

The feminine touch

T

– which has meant many retrenchments, with large percentages of women facing the axe. An array of speakers from the mining industry will take to the podium at

HE FIRST quarter of 2016 sees the

industry. The 2015 edition of WIM saw a

the 2016 gathering. Speakers will feature

staging of one of the most promi-

gathering of women from across South-

from South Africa and also, offering a con-

nent mining events in the industry.

ern Africa that sparked unprecedented

tinental perspective, from the African Un-

From 17 to 19 February 2016, Intelli-

discussions and excessive knowledge ex-

ion; there will be international case studies

gence Transfer Centre (ITC) will be hosting

change. Speakers highlighted that wom-

from Australia and governmental and

the 7th Annual Women in Mining (WIM)

en are born leaders and are assets to the

regulatory addresses from Namibia.

conference, which will look at not only the

mining industry. The main theme that res-

The faculty of South African speakers will

integration but also the development of

onated through the conference was the

showcase prominent trendsetters within

women in mining.

importance of introducing structures within

the mining sector and, at the same time,

Although South Africa has the highest

mines that will enable the continuous de-

women who are “fighting the fight” at

number of women serving on the boards

velopment of women. The 2016 edition of

grass-roots level. Women within mining

of mining companies in the world, the

WIM is being produced to deliver hard-hit-

can only grow from attending confer-

ratio is still significantly low. The aim of the

ting presentations, which will be driven by

ences of this magnitude and WIM is tes-

conference is to create an objective plat-

case studies, on current opportunities and

tament to ITC’s commitment in bridging

form where women can network, learn

overcoming possible challenges. Over the

the gender gap within the mining sector

from each other’s experience and mentor

last six months, immense industrial action

through intensified research and peer-to-

each other to thrive within the mining

has impeded many mining companies

peer learning.

Consulmet 48

Komatsu South Africa

Department of Water & Sanitation

LiuGong OBC

index to advertisers 6th Annual Enviro Mining

24

7th Annual Women in Mining

56

Akron/Dosetech 50

Dispro Tech SA

ALG Relining and Rubber Lining

DRA Mineral Projects SA

55

4 44 OFC

Aquadam 46

Drillcon 28

Barloworld Industrial CAT

Emerald Risk Transfer

IBC

BMG 43

Feedback & Recommendations Will Be Forwarded To Key Authorities After The Conference

2

Inyatsi 26

30

Mining Indaba

52

Polypipe 42 SRK 20 Tega Industries

38

Thyssen Krupp

1

WorleyParsons 11 CPD ACCREDITED 3 POINTS (1 PER DAY)

7th ANNUAL

WOMEN IN MINING

-Moving From The Integration To The Development Of Women In Mining Date: 17, 18 & 19 February 2016

venue: Indaba Hotel, Fourways, Johannesburg

CONFIRMED SPEAKERS INCLUDE:

•

MINISTRy OF MINES & ENERGy NAMIBIA DEPARTMENT OF LABOUR LONMIN ANGLOGOLD ASHANTI SASOL MINING MINING QUALIFICATIONS AUTHORITy DE BEERS SIGHTHOLDER SALES SOUTH AFRICA (DBSSSA) RICHARDS BAy MINERALS ANGLO AMERICAN PLATINUM

• • • • • • • •

• • •

• • • • • • •

Conference Highlights Re

se

56

ar

ch

ed

&

Join ITC after day one for a 30 minute “time out” pamper massage

De ve lo

pe

d

PRACTICAL WORKSHOPS FOCUSED ON WOMEN IN MINING

PETRA DIAMONDS BLACK ROCK MINING OPERATIONS SASOL MINING (PTy) LTD-BRANDSPRUIT • COLLIERy • THARISA MINERALS AFRICAN UNION CHAMBER OF MINES NAMIBIA PALABORA COPPER (PTy) LIMITED MCCONNELL DOWELL CONSTRUCTION (AUST) PTY LTD DOWNER MINING

Register and pay by 1 February 2016 and receive a gift bag filled with great surprises

COMPLyING WITH THE AMENDED LRA WHILE ADvANCING WOMEN WOMEN IN MINING - A HEALTH & SAFETy PERSPECTIvE

COCKTAIL AND NETWORKING FUNCTION WITH COMEDy

By JOEy RASDIEN

Join ITC at the end of day two for a cocktail networking function

CPD Validated by:

For easy registration contact Zakhele: +27 (0) 11 326 2501 or email bookings@intelligencetransferc.co.za or fax: +27 (0) 11 326 2960 or visit: www.intelligencetransferc.co.za

Ins i de Mi n i n g B0y1: | 2 0 1 6

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Rocktuff Pumps is a family business consisting of three brothers which started in 1991. Our customer base includes South and southern Africa. Rocktuff pumps has been a Barloworld Power customer since 1995.

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