Inside Mining July 2013

Highly commended 2012 PICA Cover of the Year - B2B Publishing

www.miningne.ws

MEDIA

HOT

THE KNOWLEDGE YOU NEED

ining FROM THE INDUSTRY EXPERTS

SEAT FIRST SOLAR

Johan Cilliers on photovoltaic energy solutions for mining in Africa P8

PRECIOUS METALS Celebrating local gold and platinum players

MATERIALS HANDLING Lifting to new heights

SPECIAL FEATURE

Infrastructure in Africa

40 years

of stacking and reclaiming at Sishen ISSN 1999-8872 • R40.00 (incl. VAT) • Vol. 6 • No. 7 • July 2013

IT PAYS TO TALK TO A SPECIALIST

Tenova Delkor is an industry specialist in solid / liquid separation and mineral processing applications for the minerals, chemical and industrial markets.

Offering comminution, flotation, sedimentation, filtration, screening, and gravity separation systems, Tenova Delkor services range from test work, process trade-offs and flowsheet design, to installation, commissioning and aftermarket support.

www.delkorglobal.com www.tenovagroup.com TENOVA MINING & MINERALS is a total integrated technological solutions provider to the mining, bulk materials handling and minerals beneficiation industries.

CONTENTS

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

ining

July 2013

FROM THE INDUSTRY EXPERTS

O ON THE COVER

Highly commended 2012 PICA Cover of the Year - B2B Publishing

www.miningne.ws

MEDIA

THE KNOWLEDGE YOU NEED

HOT

ining

ThyssenKrupp T

FROM THE INDUSTRY EXPERTS

Stacking and reclaiming play a S h huge role in operational efficiency aas capacity increases at Kumba IIron r Ore’s massive Sishen mine.

TThe Bed E materials handling eexpansion project, tasked to d deliver on such functionalities, h has been a resounding success tthanks h to ThyssenKrupp M Materials Handling.

SEAT FIRST SOLAR

Johan Cilliers on photovoltaic energy solutions for mining in Africa P8

PRECIOUS METALS Celebrating local gold and platinum players

MATERIALS HANDLING Lifting to new heights

SPECIAL FEATURE

Infrastructure in Africa

P4

40 years

of stacking and reclaiming at Sishen ISSN 1999-8872 • R40.00 (incl. VAT) • Vol. 6 • No. 7 • July 2013

12

EDITOR’S COMMENT

3

Ignoring the clouds – finding a silver lining

HOT SEAT

8

First Solar's world-class PV solutions for Africa

IN THE SPOTLIGHT

12

SACPS chairman, Kobus du Plessis

14

SACPS coal student of the year, JD Singleton

PROJECT OF THE MONTH

16

Impala 16 Shaft's rope-up record

26 PRECIOUS METALS

26

A BIOX alternative for Barbrook?

28

Evander Gold Mines earmarked for greatness

33

Goldpats refocused on South Africa and Ghana

INFRASTRUCTURE IN AFRICA

54

38

Cherishing Africa

40

Hatch Goba develops a road to sustainability

42

Consulmet's impressive infrastructure insight

45

The roles of mines and government for local infrastructure

46

Infrastructure opportunities in North and West Africa

48

African development – the signs are there

52

Top-notch satellite solutions

54

An upper-class development for Kathu miners

56

Reaping the benefits of flexible water infrastructure

58

Doorstep docking

60

Potable water storage for UMK

MATERIALS HANDLING

62

62

ARDBEL redefines large-scale materials handling

65

ConquestXP – the toughest belt yet

66

Bakubung rises to the occasion

INSID E M IN IN G 0 7 | 2013

1

EDITOR'S COMMENT

Publisher Elizabeth Shorten Editor Laura Cornish

IGNORING TH E C LOUD S

Journalist Reggie Sikhakhane Head of design Frédérick Danton Senior designer Hayley Mendelow Designer Kirsty Galloway Chief sub-editor Claire Nozaïc Sub-editor Patience Gumbo Contributor Peter Labrum Marketing & online manager Martin Hiller Production manager Antois-Leigh Botma Production coordinator Jacqueline Modise 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

Stacey Glad Tel: +27 (0)11 465 5452 Cell: +27 (0)83 567 0073 stacey.glad@lantic.net ___________________________________

MEDIA

No. 4 5th Avenue, Rivonia 2191 PO Box 92026, Norwood 2117 Tel: +27 (0)11 233 2600 Fax: +27 (0)11 234 7274/5 www.3smedia.co.za ___________________________________ Annual subscription:

South Africa: R420.00 (incl VAT & postage) African countries: US$80 Foreign: US$100 E-mail: subs@3smedia.co.za ISSN 1999-8872 Inside Mining Copyright 2013. 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.

Finding the silver lining I dedicate

this issue of Inside Mining to our industry’s positive thinkers. Why? Because it is the positive thinkers that find ways to work around adversity, and this issue is proof it can be done.

A relevant topic, wouldn’t you say, considering the commodity focus this month is platinum and gold. There is no denying that the gold price has dropped severely and the platinum sector is struggling to sustain itself on the back of illegal strike after strike …

But – and this is a big but – it isn’t all doom and gloom.

You only have to turn this issue’s pages to realise that there is not just light at the end of the tunnel, but can be seen all the way through the tunnel as well.

Let’s, just for a moment, turn our attention away from Anglo American Platinum – although I’m sure Chris Griffith won’t. Did you know that Impala Platinum is in the process of celebrating a major milestone?

Its 16 Shaft headgear is not only the tallest concrete headgear structure in Africa, but also comprises one of the largest multi-stage rope-up systems South Africa has even seen? It is nine years since this project started and is now gearing up for first production next year.

Or how about Goldplat? This AIM-listed company has announced a revised business strategy, which sees greater emphasis placed on its South African operation. Just when I thought everyone was trying to get out of their local asset obligations, here is one company that is looking to South Africa, and not the rest of Africa, for greater business returns. Now that is something worth celebrating.

Australian-listed Vantage Goldfields, a local gold junior, openly admits that investor appetite for South Africa is practically non-existent and is ‘battening down the hatches’, but is on the brink of something technologically huge – for the whole sector. It is offering an alternative processing solution to BIOX for all refractory gold players. This is HUGE and could potentially revolutionise the industry.

Evander Gold Mines – an old, old lady – with open-ended opportunity for growth, right here in South Africa – our gold industry isn’t bowing out yet. This is truly a Cinderella story in the making.

Of course I can’t mention every silver lining, but there are many more, not just in precious metals, but for every commodity, which I promise to cover in upcoming months.

Our July feature is also our branded African infrastructure issue. It is loaded with news on our continent’s future and discusses challenges associated with Africa, success stories and what our service industry is doing to make things a little bit easier for the mining houses developing portfolios in remote places.

Ending on another high note, our materials handling feature is filled with loads of exciting news. We introduce ARDBEL on page 62, which has been building headgears in record time and taking conveyor belt strengths to new levels – big developments for big mining components.

Don’t forget our cover story either, materials handling specialist ThyssenKrupp Materials Handling has done it again with large-scale stacking and large-scale reclaiming at Sishen – the largest opencast iron ore mine in Africa.

There is nothing small about this company – and nothing small about Inside Mining either!

To our avid readers, be sure to sign up and get the latest updates and inside scoop from the mining industry. Check out what we are talking about on our website, Facebook page or follow me on Twitter and have your say. @mining_news www.facebook.com/pages/Mining-News

INSID E M IN IN G 0 7 | 2013

3

COVER STORY

T HYS S ENKRUPP MATE R IAL S H AN D L ING

40 years

of stacking and reclaiming at Sishen Stacking and reclaiming play a huge role in operational efficiency and production streamlining as capacity increases at Kumba Iron Ore’s massive Sishen mine. The Bed E materials handling expansion project, tasked to deliver on such functionalities, has been a resounding success thanks to ThyssenKrupp Materials Handling, writes Laura Cornish.

4

I NS IDE MI NI NG 0 7 | 2 0 1 3

COVER COVE CO VER R ST STOR STORY ORY Y

The new 4 000 tph luffifing and slewing stacker eration, INSET New generation, larger, unidirectional TAS40 eclaimer drum reclaimer

T

HYSSENKRUPP MATERIALS Handling (TKMH), a division of ThyssenKrupp Industrial Solutions South Africa, has been supplying stackers and reclaimers to Sishen – the largest opencast iron ore pit in Africa – for over 40 years. Its latest project on-site, completed in July last year, acknowledges the instrumental role its equipment plays in the mine’s overall operational capabilities.

In each issue, Inside Mining offers advertisers the opportunity to promote their company’s products and services to the appropriate audience by booking the prime position of the front cover, which includes a two-page feature article. The magazine offers advertisers an ideal platform to ensure the maximum exposure of their brand. Please call +27(0)11 465 5452 to secure your booking.

Sishen is a large volume operation, mining about 171 Mtpa (including waste) – as reported in Kumba’s 2012 financial year-end results. And this is set to increase as the main pit dips to the west and the ratio of waste-to-product increases. Ever-increasing volumes require equipment capable of moving large tonnages of the hard rock material typical to the Sishen mine. This has resulted in various on-site projects aimed at accommodating this, including the Bed E expansion project.

“In March 2010, we were awarded the full turnkey Bed E expansion project, which had the sole purpose of increasing Sishen’s overall stacking, reclaiming and storage capacity,” explains TKMH’s marketing manager, Willie Agenbag.

INSID E M IN IN G 0 7 | 2013

5

COVER STORY

LEFT Old TAS40 in front of transfer car RIGHT Rake, buckets and drum of the new TAS40 in action

“The project, which included all civil, mechanical and electrical work, saw us remove the small TKMH stacker as well as its feed conveyor and two small TKMH TAS27.5 reclaimers that have been in operation since 1971. We then extended the bed to 40 m width and 365 m in length to accommodate a larger volume stockpile.

We upgraded and installed new conveyors, and supplied and commissioned a larger 4 000 tph luffing and slewing stacker. One of the most rewarding elements of the project was replacing the two small reclaimers with a new generation, larger, unidirectional TAS40 drum reclaimer, with its

“During the design phase we had to ensure that the new drum reclaimer would fit any of the beds.” Willie Agenbag, marketing manager, TKMH

6

I NS IDE MI NI NG 0 7 | 2 0 1 3

TAS40 drum reclaimer design, speeds and performances Parameter

Value

associated conveyors, which Type Unidirectional had to feed via a new transRail Span 40 m fer house and link conveyor into the existing system,” Maximum capacity 5 500 tph Matthias Göing, TKMH sales Machine mass 450 t (approximately) manager continues.

Drum speed variable The new drum reclaimer (a TAS40), which spans Rakes 2 off single oscillating 40 m, is equipped with 64 1 800 mm belt width, buckets and is big enough Cross conveyor belt variable speed to handle up to 5 500 tph Reclaim travel speed 37 to 220 mm/min continous throughout.

The transfer car pit was Cutting circle 6.2 m also extended to reach Bed E, Installed power ± 570 kW thereby enabling Kumba to use any of its three TAS40s Fast travel speed 2 to 15 m/min across all of its reclaiming beds (A to E) using the existing TKMH machines also perform reliably under setransfer car. The transfer car may appear to vere conditions, which in Sishen’s case inbe a simple device, but is capable of movclude high temperatures, high dust levels ing a 40-m wide machine weighing around and abrasive material characteristics – due 450 t across multiple beds. to their mechanical simplicity and gentle Even though its equipment can be dereclaim action. scribed as ‘giant-sized’, dwarfing the peo“We successfully completed the project ple who operate it, attention to the smallin July 2012, on time and within budget, est design and engineering details is essenand have a satisfied client to prove it,” actial. “During the design phase, we had to knowledges Stephen van der Walt, project ensure that the new drum reclaimer would manager for the Sishen Bed E project. And fit any of the beds, which required intereven though the TAS40 replaced two maface checks with various other equipment chines, Sishen still boasts the highest conand structures, and adaptations to TKMH’s centration of drum reclaimers in the world, latest, more operator-friendly designs, enwhich, thanks to TKMH, includes seven reabling it to move seamlessly between beds. claimers and five stackers.

While there are numerous different reMachines that keep on giving, claimer types, Göing explains that the and giving drum reclaimer delivers the best blending While the capital outlay for a reclaimer or results at constant high throughputs. “The

COVER STORY

stacker is significant, the payback return is quick. “Our fully automated machines must work continuously for the majority of their lifespan.” TKMH reclaimers (and stackers) are no stranger to the demanding requirements of Sishen and have successfully met the mine’s needs for decades.

Every TKMH machine ever supplied to Sishen that is still on-site remains operational today, which for some machines equates to 40 years. “We are extremely proud of this, considering a typical reclaimer or stacker is designed to operate for between 25 and 30 years with the correct maintenance.

“This means that our original machines have delivered many more years than the expected lifespan of what they were originally designed to do. The new generation machines, including small design modifications to meet the needs of the specific material and movement requirements, are expected to deliver even longer lifespans – if operated correctly and maintained properly,” Agenbag notes.

Stacker design, speeds and performances Parameter

Value

Type

Luffing, slewing and travelling with C-frame upper structure and coupled travelling tripper

Boom length

Head pulley to the slew centre = 30.25 m

Stacking capacity

4 000 tph (nominal)/4 500 tph (peak)

Luffing

-10 to +14 (hydraulic)

Travel speed (max)

20 m/min

Travel speed (min)

6 m/min

Rail span

5m

Boom belt

1 350 mm belt width

Mass

320 t approximately, including counterweight

Truly local TKMH prides itself on being a truly South African company. All design and fabrication work is performed and undertaken locally, which provides employment opportunities and substantial benefit to local communities.

Machines pushing past their limit 1971 TKMH supplied two TAS27.5 drum reclaimers to the south plant (no longer operating).

1973 TKMH supplied two stackers, two TAS40 drum reclaimers and a transfer car; the reclaimer drums featured the double shell design.

1979 TKMH supplied a system for handling coalcrete overburden, including a semi-mobile crusher and a crawler mounted spreader.

Late 1980s TKMH changed its reclaimer drum design to a single shell.

2005 to 2008 TKMH supplied four TAS41 drum reclaimers (two for ROM and two for product), three stackers and a second transfer car as part of the Sishen Expansion Project.

2009 to 2010 TKMH supplied one of TAS41 product drum reclaimer.

2010 to 2012 Bed E expansion project, including a larger replacement stacker and a single drum reclaimer, replacing two smaller ones.

In each issue, Inside Mining offers advertisers the opportunity to promote their company’s products and services to the appropriate audience by booking the prime position of the front cover, which includes a two-page feature article. The magazine offers advertisers an ideal platform to ensure the maximum exposure of their brand. Please call +27(0)11 465 5452 to secure your booking.

INSID E M IN IN G 0 7 | 2013

7

HOT SEAT

F IR S T S OLA R

World-class

PV solutions for Africa

Leading global photovoltaic (PV) energy solutions provider First Solar has installed over 7GW of major utility-scale renewable energy around the world.

Considered an industry leader, the company is looking to introduce and share its technology with the Southern African mining market, writes Laura Cornish.

8

I NS IDE MI NI NG 0 7 | 2 0 1 3

HOT SEAT

and appointed energy expert Johan Cilliers as regional director for the sub-Saharan African region.

Cilliers’ professional career has been spent in the energy sector, working most often with the mining industry, which recently includes working at Eskom and General Electric. He brings extensive local industry experience to the First Solar group and is working to introduce, showcase and position First Solar on the African map.

“We are here to help Africa and its biggest energy consumers find solutions to their power constraint difficulties. We are ready to share our knowledge and work closely with the local sector to meet its pressing energy needs,” Cilliers states.

S

INCE ITS ESTABLISHMENT in 1999, the Nasdaq-listed company’s installation base is growing rapidly as the demand for clean, reliable and efficient renewable energy technology gains popularity and recognition. The success of the world’s leading provider of comprehensive PV solar energy solutions, speaks for itself with 7GW of modules produced and a contracted pipeline of 3GW. South Africa is currently going through a major transformational period as it works to diversify its current energy mix. The region is desperate for clean energy, especially major industrial energy users such as the mining industry, whose future production profiles remain dependent on energy supply from Eskom-alternative sources.

Having established itself so successfully around the globe, First Solar is now looking to make its mark in Southern Africa – and South Africa in particular. The company established a local office in August 2012

Why PV, why First Solar?

First Solar is not just another PV player. It has spent years researching, developing and refining its record-holding thin film technology, which is considered one of the best in the world.

Nicholas Strevel, First Solar technical sales manager, outlines the multiple benefits that PV technology has to offer. “First and foremost, it converts sunlight directly into DC energy without lengthy or complicated processes.”

Other advantages are that: • it is cost competitive in most markets • it can be installed modularly and added to the grid quickly • it uses bankable technology • it helps stabilise the grid • it does not use any water when in operation (like concentrated solar power) • it can be used in different applications such as utility-scale power plants and off-grid diesel/hybrid systems

Sheikh Mohammad Bin Rashid Al Maktoum Solar Park – Dubai, United Arab Emirates First Solar is constructing a 13 MW DC solar PV power plant for the Dubai Electricity and Water Authority (DEWA) in the United Arab Emirates. Under the terms of the agreement, First Solar is providing engineering, procurement and construction services, as well as its advanced thin-film PV modules.

The solar PV power plant is the first phase of the landmark Sheikh Mohammad Bin Rashid Al Maktoum Solar Park, named after the leader of the Emirate of Dubai, an AED 12 billion (R32.75 billion) project that is expected to eventually cover 48 km² and produce 1 000 MW of clean energy for the national grid using both PV and solar thermal technology.

PV technology converts sunlight directly into energy INSET First Solar has achieved system availability of over 99% for the fleet of utility-scale PV plants

Once completed, the 13 MW power plant is expected to generate more than 22 million kilowatt hours of electricity per year, on average, enough to meet the average annual electricity needs of more than 500 local households. Electricity generated by the power plant on average will displace more than 14 000 metric tonnes of carbon dioxide annually, equivalent to removing 1 600 cars from the road every year.

INSID E M IN IN G 0 7 | 2013

9

HOT SEAT

• it helps reduce the region’s carbon dioxide emissions.

In addition to the general benefits of PV, First Solar has taken the technology to a whole new level. By gaining industry-leading capabilities across the entire solar value chain, to become the world’s leading provider of PV energy solutions, First Solar is able to offer cost competitive prices. “We manufacture black, uniform panels comprising two thick sheets of glass with a thin plastic middle inner sheeting and no frame. Thanks to a streamlined, fully automated process, we can manufacture panels in just two and a half hours – substantially faster than the process required to manufacture conventional crystalline silicon panels,” Strevel continues.

Matt Merfert, Middle East and Africa EPC director, explains what he believes to be one of the company’s leading technological innovations: the single axis tracker. “Unlike conventional trackers that use a centralised motor to rotate large PV panel quantities, we use a distributed actuation architecture, which in essence means many smaller motors are distributed across the site.”

This has numerous benefits, including: • minimal impact of any single point failure • eliminates emergency repairs • no row-to-row links, making construction and operation easy • not impacted by soil setting • obstruction sensing at row level • high resolution data/visuals, which equates to fast and precise diagnostics • repairs are inexpensive, requiring only hand tools and a few minutes

Agua Caliente solar project – Yuma County, Arizona, US First Solar constructed a 290 MW solar project located on 2 400 acres of previously disturbed farmland. The Agua Caliente project, initially developed by NextLight Renewable Power, is now being completed by First Solar, which acquired NextLight on 12 July 2010. On 3 August 2011, NRG Energy acquired the Agua Caliente project and on 18 January 2012, MidAmerican Renewables acquired a 49% stake in the project.

First Solar will continue to build, operate and maintain the project. When fully operational, the project will generate enough clean solar energy to serve the needs of about 100 000 average homes per year, displacing approximately 220 000 t of carbon dioxide annually – the equivalent of taking about 40 000 cars off the road.

Compensating South Africa’s biggest challenge

Meeting the needs of the sub-Saharan African mining sector

From a financial point of view, First Solar understands renewable energy and PV associated risks, which are especially high in South Africa where investor uncertainty is high in a new market.

“Because our installation base is so high, clients can rest assured that from a technological perspective, First Solar offers very little risk. Financially, our balance sheet is over US$1 billion (R10.11 billion) and our market cap is US$4 billion. Because our solutions cover the entire PV value chain, from studies through to financing, constructing, operating and maintaining, we can solve any problem,” says Stewart Bewley, First Solar project

While First Solar will participate in goverment’s third round of independent power producer tenders, it is predominately focused on providing customised solutions for individual clients.

“The mining industry has come a long way since 2008 when South Africa’s energy crisis became a reality. Despite its progress, I believe there are still a lot of inefficiencies that the industry and government must work to overcome,” Cilliers reveals.

One of his priorities for the mining sector is to provide PV systems that can be run in conjunction with installed energy bases.

“Many mining companies in Africa run on diesel-driven generators, which are very costly to operate. By running a PV plant in the day, we can curtail a lot of generator and fuel costs. We are already looking at a number of projects in this area, where the target is stretching base load supply.”

Combatting another area of concern, Cilliers explains that First Solar has opted to work with selected EPC companies for plant construction. “We want to teach and transfer our knowledge. We want to develop inter-country relationships and help Africa to work together and build infrastructure for its people and create jobs.”

“Our purpose is to be profitable and successful, while helping the industry build its expertise. Mining companies should have the option to purchase our power and not have to pay for the plant that produces it. This forms a large component of our PV energy plan.”

According to a 2012 UN report, Africa’s solar energy market will be worth USD$57 billion by 2020. “If only 10% of this amount is realistic, the opportunities are still huge.”

“We are here to help Africa and its biggest energy consumers find solutions to their power constraint difficulties.” Johan Cilliers, First Solar regional director for sub-Saharan Africa • the design provides the highest mechanical availability and the lowest operations and maintenance of any tracker technology.

Merfert does not deny that PV technology is reliant on the sun, “but we really are part of a larger, complex system, and because we don’t rely on magnets or spinning turbines, we can contribute to voltage stability. Our systems are rugged enough to withstand extreme weather conditions (wind, hail, heat), but are complex enough to predict weather patterns and can even increase output from unaffected areas when cloud cover spots occur.”

10 I NS IDE MI NI NG 0 7 | 2 0 1 3

financier. He adds that, once installed, a First Solar power plant can produce electricity at a rate that would be cost-competitive to power supplied by utilities companies in as little as five years.

First Solar has achieved system availabilities of over 99% for the fleet of utility-scale PV plants under operation. Because repairs and maintenance take place at night, availability is not affected at all. Plants are engineering for 25 years plus and this year the company will celebrate the ongoing successful operation of its oldest installation, which has been operational for 18 years.

SMART SOLUTIONS TO FUEL PRICE VOLATILITY. SOLAR IS JUST HOW WE GET IT DONE. Solar is cheaper than diesel, or any liquid fuel source for that matter. With fixed pricing and no fuel price volatility, solar hedges against rising fuel costs while reducing your operational expenses. Think of solar as a source of fuel, not additional capacity.

Our Hybrid Plant Solution combines photovoltaic solar energy with existing thermal generation to

First Solar South Africa | W: +27 21 488 1010 | firstsolar.co.za

reduce fuel consumption and save costs by up to 40%. We have delivered PV plants that are 250MW in size and incorporate advanced plant controls and accurate energy forecasting to ensure bulk power reliability and stable grid integration. To see what we can do for you, contact africa@ďŹ rstsolar.com.

IN THE SPOTLIGHT

S AC P S CHA IRMA N KOBUS D U PL E S S IS

Committed to training

The newly appointed chairman of the Southern Africa Coal Process Society (SACPS), Kobus du Plessis, will focus his two-year tenure on further promoting and endorsing education and training in the coal sector, writes Laura Cornish.

E

DUCATION AND TRAINING embodies the purpose of the SACPS. Considering our country will continue to rely heavily on coal for its power needs beyond the foreseeable future, developing our future coal engineering generation is as essential now as it ever was,” outlines Du Plessis, who is also a director at Malvern Engineering.

caters to the ‘men on the coalface’, is also well received and recognised for its contribution to improving current industry challenges.

The SACPS recently donated a specialised piece of equipment to the School of Chemical and Minerals Engineering at North-West University. The IKA C5000 Automated Bomb Calorimeter was set up in 2012 and has proven to be an essential investment. This special

“South Africa has one of the most advanced coal processing programmes in the world.”

Kobus du Plessis, chairman of SACPS The 300-member non-profit society works closely with North-West University (Potchefstroom campus), the eMalahleni-based Colliery Training College and the University of Pretoria. Its annual winter school, which

12 I NS IDE MI NI NG 0 7 | 2 0 1 3

piece of equipment measures the heat values of coal, which is used in almost all coalrelated research to quantify characteristics.

It can also be applied to other combustibles, like biomass.

For the undergraduate and postgraduate students working and operating the machine, the benefits are endless. Calorific value measurements are standard and routine for any coal work, but students can now perform quick and accurate analyses for their projects. Analyses would have to be done externally otherwise. In its endeavours to raise funds through its conference sponsorships, attendance and membership, the SACPS hopes to continue with projects such as this to benefit the coal industry as a whole.

Du Plessis indicates that the society has a positive bank balance, thanks to various fundraising initiatives, and is looking forward to sponsoring projects “for the right reasons”.

Reiterating the coal sector’s importance, the new chairman reveals some interesting coal facts: • Primary global energy demand will increase by over a third between 2010 and 2035.

IN THE SPOTLIGHT

and education This growth is as a result of the rising living standards in the emerging economies especially in China, India and the Middle East, where coal demand for electricity generation will continue to grow.

• In 2012, the saleable coal produced amounted to approximately 250 Mt. • Approximately 75% of coal produced in South Africa is used domestically and 25% is exported.

• The coal business employed close to 80 000 people in South Africa and paid more than R16 billion in salaries.

• There is still about 60 billion tonnes of coal reserves available in South Africa.

• New mines with coal processing plants are being planned at various locations to provide feed to the local and international power stations over the next few years.

“Thanks to the efforts and commitment from so many industry professionals and experts, South Africa has one of the most advanced coal processing programmes in the world and the society has every intention of continuing this legacy. We have the passion and the drive to keep abreast of the challenges associated with the beneficiation of coal and will support upcoming coal engineers with initiatives to take the industry forward.

“In America and Australia, the average coal processing engineer is over 50 years of age, in South Africa it is over 40. We need to fill that gap to ensure industry advancement, particularly with regards to more efficient technologies that are more user-friendly.”

The SACPS also works in conjunction with Coaltech 2020 – a collaborative initiative aimed at developing technology and applying research findings that will enable the South African coal industry to remain competitive,

STRATEGIC PARTNERS

sustainable and safe well into the 21st century. And dedication to this commitment is undoubtedly evident. The society is currently putting together a new handbook, which will be ready for release towards the end of the year or the beginning of next year. It brings together insightful information from various experts from various coal-based industries and is aimed at helping the industry keep in trend with new technologies and processes.

Effective and economical beneficiation of fine coal is generally viewed as the next major contribution to solving problems in coal mining. Further studies to reduce the negative impact of environmental slimes ponds and discard dumps can be undertaken with further funds – challenges the industry is desperate to resolve and improve on.

Coal man of the year At the SACPS annual dinner held in May, Du Plessis announced that Peter Lidgate was ‘coal man of the year’. Lidgate is one of the stalwarts of the industry who has made an outstanding contribution in the area of coal preparation.

“I am honoured to receive this recognition, especially given some of its most distinguished recipients, and I would like to thank the committee for their support. Success in a particular field is often a result of the people that surround you and in this regard I have indeed been fortunate to have been surrounded by enthusiastic, capable and competent people. Particular thanks to Adriaan van der Berg who employed me at Trans-Natal and supported me wholeheartedly during my 10 years with Trans-Natal and Ingwe.”

Born and bred right here - Bell is Africa’s very own global equipment supplier. With Bell you get machines built tough for our harsh environment and support from Africa’s most comprehensive network of people dedicated to your success.

Best of all, while you are creating infrastructure and jobs, so are we.

Choose Bell as your equipment partner and enjoy the pride of knowing you’re not just boosting your business but helping make Africa a better place too.

BOTH Typical coal washing plants in South Africa.

Thanks to the efforts and commitment from so many industry professionals and experts, South Africa has one of the most advanced coal processing programmes in the world

Tel: +27 (0) 11 928 9700 E-mail: sales@bell.co.za www.bellequipment.com

I N S I D E M IN IN G 0 7 | 2 0 1 3 13

IN THE SPOTLIGHT

WEIR M INE RA L A FRICA'S J D S IN G L E TON

SACPS coal students of the year Southern African Coal Processing Society (SACPS) student of the year, JD Singleton, celebrates and acknowledges the role advanced cyclone technology is playing in the coal industry, writes Laura Cornish.

S

INGLETON IS FROM the School of Chemical and Metallurgical Engineering at the University of the Witwatersrand, where he is currently completing his master’s dissertation.

His topic for the student award was “The development and evaluation of a dense merican mindia cyclone for the Southern African eton was erals and coal industries”. Singleton alcon nominated by Prof Rosemary Falcon of the Fossil Fuel Foundation. In addition to the work on his topic, her nomination stated that he was an n exceptional research candidate in terms of innovativeness, thor-oughness, clarity in his writing and conscientiousness.

Singleton will be presenting a paper, “Latest classification cyclone technology improves overalll plant performance at Phola Coal”,, at nferthis year’s Coal Processing Conference, which will be held in July.

RJ Spargo technologies, which was acquired

by Weir Minerals via its acquisition of the Linatex group of companies in 2010.

“The acquisition of the Linatex group immediately gave Weir Minerals a 65-year cyclone design and manufacture legacy.

Combining this with our Cavex cyclone technology, my team and I have played a n

A shoo-in Singleton joined Weir Minerals Africa in 2009 and was recentlyy he appointed process manager for the ge, entire Weir Minerals product range, ellwhich includes Weir Minerals’ wellnce known Cavex cyclone brand. Since nt joining the company, he has spent his time harnessing his passion for equipment development to drivee the ex cyclone expansion of the company’s Cavex ynergies of range, as well as leveraging the synergies

Cavex cyclones offer a unique solution for slurry applications and have been designed to deliver maximum efficiency and capacity

14 I NS IDE MI NI NG 0 7 | 2 0 1 3

instrumental role in developing a feed chamber lining in cyclones using ceramic tiles for the coal industry, while staying true to the unique Cavex cyclone shape,” says Singleton.

The new technology, widely accepted in hard rock applications, was first implemented at the Phola Coal process plant and has been a major success. The plant is jointly owned by Anglo American Inyosi Coal and BHP Billiton Energy Coal South Africa.

After installing and commissioning eight Cavex cera ceramic lined cyclones at Phola, the metallur metallurgical department at the plant not noticed an immediate improvem ment. There was a 49% increase in s solids reporting to the underflow b comparison with the original by c cyclones.

An additional 24 tph of solids reported to the underflow compared to the original cyclones and they produced a finer cut with an average d50c o of 107 microns as compared to an average d50c of 210 microns pro produced by conventional cyclones.

A As a result, an increased solids load loading of 24 tph per cluster onto the sspirals increased the saleable yyield. Plant availability also increased and downtime has been r reduced.

Due to these substantial improvements, 18 additional Cav cyclones were subsequently Cavex ins installed at Phola Coal. Weir Miner erals has subsequently received a replacement cyclone order on ano another existing installation at a High Highveld Colliery. “The business is a sp direct spin-off from Phola.” desig used in Cavex brand cyclones The design was origina originally developed by Warman International (now Weir Minerals Australia) in Australia in the 1980s in response to industry concerns relating to cyclone wear and reduced efficiencies in grinding circuits.

IN THE SPOTLIGHT

Typical feed designs are 75- and 180-degree involutes. Existing The end result is greatly reduced turbulence creating more even wear, designs were prone to wear near the inlet as a result of turbulonger life and more efficient classification.” lence and coarse particle scouring.

The original cyclone C-range from “Cavex cyclones offer a unique Warman International grew in solution for slurry applications in Australia until the late 1990s after the mining and mineral processing which the new generation cyclone Singleton’s background industry and have been designed feed chamber was introduced to the to deliver maximum efficiency Cavex brand range.

JD Singleton holds a National Diploma in Engineering (Metallurgy) and capacity, while providing lon“Since 1998, our Cavex brand cyand a BTech in Engineering from ger wear life than conventional clones have become one of the most Tshwane University of Technology, designs,” Singleton says. “These sought-after classification equipas well as a Graduate Diploma in cyclones provide enhanced dewament in numerous mining countries Engineering from the University of the Witwatersrand. He recently tering and desliming efficiency, across the globe, focusing on hard completed a MSc in Engineering at reduced product loss, improved rock mining applications. Based on the University of the Witwatersrand. product recovery and increased our successful designs, coupled with Singleton actively contributes to the development circuit capacity by minimising the the RJ Spargo legacy, I am certain of the industry and is accredited as a Professional quantity of material escaping to that our ceramic-lined cyclones Engineering Technologist by The Engineering Council of South Africa. He holds memberships to the Southern the underflow or overflow streams. will be successful in the coal sector African Institute of Mining and Metallurgy (SAIMM), “Their distinctive design provides where the benefits are substantial,” the South African Coal Processing Society (SACPS) a natural flow path for slurry maSingleton indicates. and the Fossil Fuel Foundation (FFF). He co-authored terial. The unique shape has no “The fact is simple: ceramic linings the paper “Development of a viable process for the recovery from zinc oxide ores”. sharp edges, no square corners and mean less downtime in coal, and allows the feed stream to blend are accepted in the industry as the smoothly with the rotating slurry inside the unit, minimising longer lasting material of choice for coal applications. Classification cylocalised wear on the feed chamber and vortex finder. These declone principles in coal and hard rock mining are exactly the same and sign improvements result in lower operating costs and fewer should be treated the same.” cyclones required for a given duty.

STUDENT OF THE YEAR

The second student award The second student award rotates annually through the local training centres and this year’s award went to Nelson Mahulane from Colliery Training College (CTC).

His training achievements include the completion of his Basic Coal Processing course in 2007 where he obtained 90% for theory and 99% for practical. He received the CTC merit award for best Basic Coal Preparation student for 2007.

During 2012 he completed the Advanced Coal Preparation course with an average of 78% and was also awarded the CTC merit award for Best Advanced Coal Preparation student for 2012.

Mahulane is currently employed at BHP Billiton Energy Coal South Africa’s Middelburg Mine South Plant.

I N S I D E M I N I N G 0 7 | 2 0 1 3 15

PROJECT OF THE MONTH

I MPALA 16 SHA FT

Rope-up record The completion of Impala Platinum’s new deep level 16 Shaft is a major milestone in the mine’s history. It boasts Africa’s tallest concrete headgear (108 m) as well as the largest and most technologically advanced multi handling rope-up system South Africa has even seen, writes Laura Cornish.

I

MPALA PLATINUM’S (Implats) 16 Shaft project, launched in 2004, is one of three critical new greenfield replacement shaft developments (the others being 17 and 20), which must meet production start and ramp-up timelines to ensure the company’s platinum output remains stable.

Nine years down the line, one of the final activities before commissioning of the shaft infrastructure was roping up.

This means that production start-up remains on schedule for 2014, with ramp up to its 226 500 tpm nameplate capacity expected in 2018.

This is a great achievement for both Implats and Read, Swatman & Voigt (RSV) and a testament of a successful and supportive EPCM and client relationship under the guidance of client representative Frikkie Höll, general manager at 16 Shaft.

The Implats 16 Shaft

complex comprises of a vertical man/material and rock hoisting shaft (main shaft) using tower-mounted Koepe winders, with an upcast ventilation shaft. The main shaft (sunk

by Shaft Sinkers) is a 10 m diameter (inside concrete lining) shaft with an ultimate depth of 1 682 m below surface.

“What makes this project unique to the Implats asset portfolio is the interesting design factors for the winders and hoisting technology that has been implemented inside the concrete headgear,” says Torra Engelbrecht, group construction manager for RSV. RSV is the EPCM contractor for the 16 Shaft project and will forever be recognised for its commitment to technological advancement and innovative approach.

“Unlike the more traditional headgear installation methods in South Africa – such as steel headgears and ground mounted Koepe or Blair multi-rope winder systems, which usually suffer significant wear and tear – we believe our use of a tower-mounted Koepe friction winder system, together with the associated rope handling equipment, will showcase an international tried and tested methodology encompassing the most advanced technology, practices and techniques. Even more impressive is the

Headgear concrete poured reinforcing steel steelwork installed height from bank total height inside dimensions wall thickness

10 200 m³ 1 300 t 680 t (10 floors) 108.73 m 131.93 m 18 x 19 m 950 mm reduced to 550 mm

Main 108 m concrete headgear with cage installation crane

16 I NS IDE MI NI NG 0 7 | 2 0 1 3

PROJECT OF THE MONTH

Impala 16 shaft Gerhard Potgieter, Implats’ projects executive, says: “This new shaft is the second of our fourth generation Impala shafts, which have constituted the vast majority of Implats’ capital expenditure programme over the past few years.

The first shaft to be commissioned at Impala was the No 20 shaft complex in 2012; the second was the No 16 shaft complex in 2013; and the third is the No 17 shaft, which is still being developed. In addition, Implats has invested in the Zimplats Phase 2 project.” The combined impact of the new shafts being commissioned and developed in Rustenburg will, over the next five years, increase the ratio of Merensky Reef milled. The forecast is that this will increase from the current 43% of total throughput to 50% due to the exploitation of reserves at the new No 20 and 16 shaft complexes. The increased Merensky production will have a beneficial impact on both head grade and recoveries.

fact that this suite of rope-up equipment application is a ‘once in a decade’ event.

The last roping-up of Koepe winders using the modern friction winch and clamp lifting device application in South Africa took place at the Palabora mine in 2001,” Engelbrecht explains.

Due to the headgear’s proximity to surrounding communities, the headgear accommodates an internal tipping arrangement to reduce noise levels – another impressive and unusual project element. There are two 25 t skips that will tip into a 350 t capacity bin situated in the headgear on the conveyor level, which will carry the ore from the headgear to the silos. The first ore from underground is scheduled toward the end of July 2013.

With so many elements situated inside the headgear at various levels, a 60 t overhead crane mounted in the top section of the headgear was used to ensure all components were placed safely within the correct areas.

The speed of this project can also be attributed to the simultaneous activity of headgear equipping and shaft sinking. “We built the sinking headgear inside the concrete headgear structure, which was fully functional, with ground-mounted kibble and stage winders.”

Interesting facts and project highlights • the first application of concrete pumping in a slip-forming application of a headframe in South Africa • the first shaft at Implats to successfully sink through major water intersections • the first shaft at Implats to traverse the Hex River fault, without any incidents.

ABOVE Messenger winches

Why the tower-mounted Koepe friction winder system?

BELOW Friction winch

A lot of time and effort was spent evaluating the best methodology for the project.

“We evaluated winders and rope-up systems

INSID E M IN IN G 0 7 | 2013 17

PROJECT OF THE MONTH

Koepe winder specification 54 mm full lock coil winding rope with a minimum break force of 2 668 kN Three-phase synchronous motor • rated output: 4 300 kW • full speed: 57.3 rpm Technical specifications Rock winder

Man winder

Payload

25 000 kg

22 500 kg (man winder)

Tower mounted Koepe winders

Conveyance mass

26 500 kg

31 000 kg

Counter weight

NA

42 250 kg

Length of wind

1 640 m

1 601 m

Number of ropes

4

4

Rope speed

16 m/s

16 m/s

Cycle time

142 seconds

217 seconds

Head rope diameter

54 mm

54 mm

Head rope breaking force

2 668 kN

2 668 kN

Head rope type

Full lock coil

Full lock coil

Tail rope diameter

59 mm

59 mm

Tail rope type

34 compact strand (no spin)

34 compact strand (non spin)

Tail rope breaking force

2 375 kN

2 375 kN

from around the world, performing tradeoff studies with installations (and ropes) in Germany, Canada and South Africa.”

“The result of our decision was based on numerous additional benefits.” Not only is the implementation time frame to completion much faster, but the lifespan and wear and tear on the components, particularly the ropes, is lengthened considerably. In fact, less maintenance on the winder ropes is required – impressive considering they will travel at 16 m/s and must be in operation 19 hours a day, 23 days a month,” Engelbrecht notes.

The men and material Koepe winders will support one 32 t cage, comprising two decks capable of transporting 150 people per deck. Shift capability includes 2 488 people every hour. Two service cages will run on a ground mounted conventional double drum winder. 

At the bottom of the headgear, below the bank level, a closed-off tunnel passageway for personnel loading for shifts has been incorporated at sub-bank level. This has been incorporated for safety reasons and will ensure proper monitoring of every individual starting or ending a shift, Engelbrecht notes.

18 I NS IDE MI NI NG 0 7 | 2 0 1 3

PROJECT OF THE MONTH

The main headgear elements • two identical 6.5 diameter friction Koepe drum winders, 91 m above bank elevation, each with a 4 300 kW motor – supplied by ABB and subcontractor FLSmidth • mobile friction winch (the heart of the ropeup technology) • clamp and lifting device 59 m above bank elevation – same level as permanent deflection sheaves • permanent deflection sheaves (in the headgear) • ground-mounted rope reelers • messenger winches • ground-mounted deflection sheaves and compression beams.

A global first Designed in conjunction with RSV and Winder Controls, a member of the shaft hoisting specialist Siemag Tecberg Group, the scale of the rope system (installing four tail ropes from surface) is a first for South Africa and, according to Engelbrecht, is currently the most advanced methodology in the world. The only double-faced clamp and lifting device in the world, the system allows for safe handling Deflection sheave wheel and clamp and lifting device

20 I NS IDE MI NI NG 0 7 | 2 0 1 3

PROJECT OF THE MONTH

of all ropes simultaneously, e.g. for • Koepe maintenance and operating costs rope attachments and conveyance are lower (the costs are based on 20 years at replacement and maintenance. It full production) will also allow the mine to return • Terrace layouts take up considerable space for to production quickly after routine conventional winder buildings.

INTERESTING maintenance procedures. The 150 t INFRASTRUCTURE Keeping it on record mobile friction winch is used for Lesotho and South Africa have, in principle, Engelbrecht indicates that due to the high sucthe simultaneous installation of all agreed upon the R12 billion second phase of the Lesotho Highlands water project. cess already achieved on the project, Implats, toropes and will ensure fast and safe It will boost water supplies to South Africa gether with Rio Tinto, BHP Billiton and Siemag changing of all the winding ropes. while generating hydroelectric electricity. The Tecberg are jointly investing in the compilation Because it is mobile, the machine expansion will increase supply from Lesotho of a DVD on the headgear rope-up technology. will be transported to the nearby Highlands to South Africa to 45.5 m3/s.

It will be used to train artisans and technical Impala 17 Shaft to perform the Completion is planned for August 2020. personnel without requiring the presence of an same tasks.

RSV consultant.

Both Winder Controls and Engelbrecht were involved in the first and only other tower-mounted Koepe winder friction winch rope-up system in South Africa, which is Abbreviated rope-up sequence at Palabora Mining Company – the concrete headgear is 3 m shorter • reeve the head ropes up through the headgear than 16 Shaft. Next to Palabora Mining Company, 16 Shaft is only the • attach a conveyance to the head ropes second project to use this suite of rope-up equipment in South Africa.

Additional technology benefits • Koepe-type winders have lower rotational inertias and less out of balance mass to accelerate and consequently require less power to deliver the same output.

• Koepe winders are cheaper to manufacture, install and commission.

• lower conveyance to rope separation level in the shaft bottom • reeve tail ropes through the friction winch • attach tail rope to the bottom of the conveyance • install the second conveyance • connect the tail ropes to the second conveyance.

INSID E M IN IN G 0 7 | 2013 21

ADVERTORIAL

S IEM AG TEC B ERG AND W IN D E R C ON T R OL S

Vertical hoisting specialists SIEMAG TECBERG operates worldwide in two strategic fields of business: transport technology and automation and service, and is in the forefront of both these fields.

Its principal markets are mining, energy and engineering.

Siemag Tecberg has its headquarters in Haiger, north of Frankfurt am Main

Siemag Tecberg supplied a high-performance shaft hoisting system for the St Gotthard base tunnel, which it operated with its own staff up to 2012

22 I NS IDE MI NI NG 0 7 | 2 0 1 3

I

TS FIVE GROUPS of specialised products – shaft hoisting technology for raw materials, heavy-duty transport and storage technology, automation and drive technology, service and underground cooling systems – ensure perfect coverage of its target markets with a business model it describes as “engineering and knowledge-based services”.

The company’s main areas of technical emphasis are in the development, design, manufacture, commissioning and servicing of machinery used in the vertical shaft hoisting of raw materials and personnel. It possesses expertise that is outstanding in the areas of mechanical and hydraulic engineering, drive and automation technology. References from all over the world testify to Siemag Tecberg’s capabilities in general plant design and construction, while its unique selling point lies in socalled pressure exchange systems (PES) used as a “substitute for turbines” in underground mine-cooling systems.

Siemag Tecberg’s programme of products includes all the equipment required for shaft hoisting and slope-hoisting technology in mines for the vertical transport of minerals and cooling systems for underground mines and deep tunnels facing high rock temperatures.

Besides these, Company the company also philosophy supplies special Innovative machines for the products and handling and storsystem solutions age of toxic subare the driving force behind our stances and atomic thinking and waste in the unacting. Here it derground caverns is our customers of disused mines in who enjoy highest priority. addition to specialThe solutions ly modified hoistwe provide are ing technology. the very best Other products with regard to quality, reliability include special maand profitability. chines for the first roping-up of balance and guide ropes in production and service shafts as well as mobile winches for rescue and service purposes in vertical shafts.

ADVERTORIAL

Siemag Tecberg also provides technical services for on-site installation and commissioning, and in all areas of after-sales, from inspection to machine operation. Customers include companies from the raw materials and energy sector that operate underground mining facilities. Besides these, public institutions all over Europe also value Siemag Tecberg’s vast experience with machinery for storing toxic substances and low, medium and highly radioactive materials in underground caverns.

And finally, Siemag Tecberg also develops special applications for raising, lowering and relocating heavy loads in completely new areas, e.g. currently as partner of the consortium for the new Niederfinow ship lift in Brandenburg.

Siemag Tecberg is represented by at least one subsidiary on each continent.

In addition to the company headquarters in Haiger, to the north of Frankfurt am Main, it has locations in Katowice in Poland, Beijing and Tianjin in China, Sydney in Australia, Johannesburg in South Africa and Milwaukee in the US. The company has around 400 employees worldwide (2012) and the volJürgen Peschke, ume of business president and CEO of Siemag is approximateTecberg group ly €120 million (R1.54 billion), of which 90% is overseas business. The highly specialised Siemag Tecberg with its unique technology developed from a small forge founded in 1871 in the Siegerland of Germany, which (among other things) produced equipment for ore mining. Following a management buy-out in 2007, the company was

Innovation: new developments, service and new markets SIEMAG TECBERG possesses more than 50 international patents and qualification approvals. Among its own developments are various shaft hoisting machines, including a design where the drive system is integrated in the hoist drum, the only one of its type in the world. SiemagTecberg also supplies the sliding bearings for the machine shafts (over 1 000 mm in diameter) on the world’s largest hoisting machine. This project, South Deep, is operated by Gold Fields, South Africa, and is capable of overcoming depths of more than 3 km.

Among SiemagTecberg’s most important milestones are the electro-hydraulic and pneumatic disk-brake systems with corresponding brake elements, as well as mobile rope handling and rescue winches. In 2011, the world’s largest multirope friction winch was ordered for rope handling at the new hoisting plant installed in a copper mine in Mongolia.

Service with a unique character Even in the service sector SiemagTecberg is a pioneer. It developed the concept of “ten years’ operation” for the above-mentioned Gotthard base tunnel project in Switzerland, which was carried out from 2002 to 2012. This makes SiemagTecberg one of the few German engineering companies to develop and implement a concept for the operation of machinery it has supplied. It has now become part of the service package offered by the company worldwide.

Wind of change with established technology SiemagTecberg also works to apply its tried and tested technology in new areas. This means that the company is planning to enter the market for renewable energy by adapting the integrated motor design of Koepe hoisting machines for use in wind-turbine plants. Two patent applications form the basis for the future generation of environmentallyfriendly electricity using Tecberg wind-energy units.

INSID E M IN IN G 0 7 | 2013 23

ADVERTORIAL

Blair double-drum hoisting machine at Gold Fields’ South Deep Gold Mines in Johannesburg, South Africa

Milestones 1871 Origin as forge and supplier of equipment to the mining and metallurgical industries in the Siegerland, Germany 1997 Systematic acquisition of know-how and personnel skilled in the shaft-hoisting sector marks the beginning of the international expansion of the business model “Engineering and Related Knowledge-Based Services” 2000 Establishment of affiliate in Milwaukee, US 2002 Establishment of affiliate in Johannesburg, South Africa 2002 Operation of the company’s own hoisting machinery in the Gotthard Base Tunnel Project in Switzerland 2007 Management buy-out and reestablishment of Siemag Tecberg by Jürgen Peschke 2007 Establishment of affiliate in Beijing, China 2008 Start of project to reconstruct the ship lift in Niederfinow, Germany 2009 Construction of company headquarters in Haiger, near Frankfurt, Germany 2010 Establishment of affiliate in Katowice, Poland 2010 Establishment of affiliate in Sydney, Australia 2011 Acquisition of Winder Controls (automation and drive technology for shaft hoisting machinery) 2011 Inauguration of Cold Oak Customer Training and Test Centre in Haiger 2012 Construction of assembly plant in Tianjin, China 2013 Location consolidation in South Africa and China, and further integration of the business division “Engineering Business designed by Siemag Tecberg” worldwide.

re-established as Siemag Tecberg by its president and CEO Jürgen Peschke.

The following are just some of the many international references possessed by Siemag Tecberg: planning, construction and operation of a heavy-duty shaft hoisting system for the Gotthard base-tunnel project in Switzerland; supply and start-up of two Blair double-drum hoisting machines for the world’s deepest mine, South Deep, for the customer Gold Fields, South Africa; and the planning and setting up of the machinery at the temporary nuclear waste disposal site at Gorleben in Germany and the prospective ultimate disposal site known as “Konrad”.

By the end of the 1980s, Siemag Tecberg was already the market leader in the field of high-performance shaft hoisting machinery for the development of hard coal mining in China. The company also claims to be a market leader in developing the shaft hoisting capacity of the Russian and Canadian nickel ore and potassium salt industries since around 2000, and in expanding the capacity of the South African platinum ore mining industry.

Sustainability: Our goal - the customer's benefit Siemag Tecberg has a corporate policy aimed at sustainability – a concept that focuses not only on the requirements of the customer, but also the wellbeing of its employees. Thus, the PES developed by Siemag Tecberg is an

Facts and figures Industry mining machinery, hoisting technology and logistics systems, drive technology Products shaft hoisting technology, heavy load transport and storage technology, underground cooling systems, automation and drive technology Market position market leader for heavy duty Koepe and drum-type shaft hoisting machinery Turnover €110 million worldwide (2012) Employees approximately 400 worldwide (2012) Locations EPCM, service and assembly plant in Haiger, Germany; Tianjin, China (from 2013) and Johannesburg, South Africa. Other companies specialising in sales, project management and service in Katowice, Poland; Sydney, Australia and Milwaukee, US Export ratio over 90% Patents over 50 international patents and qualification approvals MINT ratio approximately 70% Founded 1871; re-established 2007 VDMA member since 2007

24 I NS IDE MI NI NG 0 7 | 2 0 1 3

ADVERTORIAL

important component in mine-cooling systems, providing a working environment for miners that complies fully with industrial regulations. It makes an essential contribution to the health and safety of mine employees – an important consideration, especially in emerging economies.

SUSTAINABILITY: OUR GOAL - THE CUSTOMER'S BENEFIT SIEMAG TECBERG has a corporate policy aimed at sustainability - a concept that focuses not only on the requirements of the customer, but also the wellbeing of its employees. Thus, the PES developed by Siemag Tecberg is an important component in mine-cooling systems providing a working environment for miners, which complies fully with industrial regulations. It makes an essential contribution to the health and safety of mine employees - an important consideration, especially in emerging economies.

CLIMATE PROTECTION THROUGH MAXIMUM EFFICIENCY

Climate protection through maximum efficiency For all new and refurbished machinery, Siemag Tecberg’s highest priorities are energy efficiency and profitability. This means that the company’s customers always receive highly efficient state-ofthe-art equipment with as low an energy requirement as possible. This allows the customer to keep the power needed for the production process as well as the CO2 emitted by the machinery in operation to an absolute minimum.

For all new and refurbished machinery, Siemag Tecberg's highest priorities are energy efficiency and profitability. This means that the company's customers always receive highly efficient state-of-the-art equipment with as low an energy requirement as possible. This allows the customer to keep the power needed for his production process as well as the CO2 emitted by the machinery in operation to an absolute minimum.

SUSTAINABILITY AT SIEMAG TECBERG's SITE At Siemag Tecberg's location in Haiger around 50% of the annual electricity requirement is generated by the company's own photovoltaic equipment.

All the roofs on the site are fitted with solar modules and plans exist to fit similar equipment progressively in the company's other locations as well. The new plant at Haiger, which was only put into service in 2009, fulfils all the requirements of energy efficiency. High priority was also given to this aspect of the company's policy when planning and constructing the new works in Tianjin.

At its home site, Siemag Tecberg has also invested in the "Kalteiche" wind farm belonging to the Haiger Energy Cooperative.

Sustainability at Siemag Tecberg’s own site At Siemag Tecberg’s location in Haiger, around 50% of the annual electricity requirement is generated by the company’s own photovoltaic equipment.

All the roofs on the site are fitted with solar modules and plans exist to fit similar equipment progressively in the company’s other locations as well. The new plant at Haiger, which was only put into service in 2009, fulfils all the requirements of energy efficiency. High priority was also given to this aspect of the company’s policy when planning and constructing the new works in Tianjin.

At its home site, Siemag Tecberg has also invested in the Kalteiche wind farm belonging to the Haiger Energy Cooperative. Siemag Tecberg and Winder Controls are proud to supply the rope handling equipment to Impala Platinum’s 16 and 17 Shaft projects.

Technikum Cold Oak training centre, which supports software development as a significant discipline of the automation engineering carried out by Siemag Tecberg

Did you know?

For more than 25 years, the PES developed by Siemag Tecberg has been in use in central mine-cooling systems all over the world. The patented system allows the alternate inward and outward transfer of fluids from a high-pressure to a low-pressure system and vice versa. For the cooling of underground mines and other facilities, the PES forms the interface between the cold water system above ground, which produces the cooling water and pipes it under high pressure to the foot of the shaft, and the cooling network below ground, which supplies the coolers for mining operations at low pressure. However, this PES technology is not used only in mining. It has also been successfully tested as an economical substitute for turbines for energy recuperation in the process of reverse osmosis in seawater desalinisation plants.

SIEMAG TEBERG 28-32 Kalteiche-Ring, Haiger, 35708 t +49 2773 91610 f +49 2773 9161300 info@siemag-tecberg.com www.siemag-tecberg.com

Winder Controls (Pty) Ltd (a member of the Siemag Tecberg Group) Unit 15, Lakeview Business Park, Yaldwyn Rd, Jet Park, 1459, South Africa PO Box 2964, Edenvale, 1610 t +27 11 383 9300 f +27 11 383 9305 info@winder.co.za

www.siemag-tecberg.com

INSID E M IN IN G 0 7 | 2013 25

PRECIOUS METALS

VA NTAG E GOLDFIE LDS

A BIOX alternative Vantage Goldfields, is showcasing its flexible business structure in response to the weak gold price. This means temporarily adjusting its growth strategy, but also validating a cost-effective BIOX-alternative refractory ore process, which will deliver substantial cost savings in the long run, writes Laura Cornish.

L

IKE ITS NEIGHBOUR Pan African Resources, Vantage Goldfields continues to deliver quality ounces from one of South Africa’s oldest goldfields: the Barberton Greenstone Belt.

Its two primary assets, Lily and Barbrook, hold sufficient resources to see the company reach its mid-term growth target of 100 000 ozpa (35 000 ozpa from Lily and 65 000 from Barbrook).

“We are, however, currently contending with the sudden drop in the gold price. This means tightening our belts slightly and holding back on our growth strategy, for now,” says the CEO, Mike McChesney. “We will focus exclusively on driving costs down and generating as much cash flow as possible by maximising on gold production from our operations.” As such, Vantage Goldfields

26 I NS IDE MI NI NG 0 7 | 2 0 1 3

expects to deliver between 40 000 and 45 000 ozpa for the time being.

McChesney is not surprised to see a correction in the gold price but is surprised by the magnitude. The weakening of the rand, however, means that Vantage Goldfields can, in fact, deliver on its budgeted targets.

“Our business is sustainable if the market stays like this,” he adds.

Lily McChesney says that, although the company ended 2012 on a high, the start to 2013 was not as fortunate. “We suffered an underground pillar collapse in the first quarter, which has been quite a set-back to operations. Lily currently contributes 80% of our total gold production. The rock failure in a primary stope was due to localised faulted

ground, which we managed to mine through satisfactorily on other levels. Despite our care in mining the weak area, the pillar still collapsed. Fortunately, we did not have any injuries, only the loss of a remote loader.”

After a three-month period of reduced production due to the loss of the stope, McChesney says Lily is making a good recovery and production levels are, again, climbing steadily. “We should achieve between 25 000 and 30 000 oz from Lily this year, not quite at her full production capabilities (about 35 000 ozpa), but nearly.”

Lily is a shallow mine – only 200 m below surface at present, which will extend to 300 m over the next year and ultimately to 500 m. It has a wide ore body and, at The Central Metallurgical Complex

PRECIOUS METALS

for Barbrook? full production, will be a relatively lowcost operation with an expected 11-year lifespan remaining.

Barbrook The real long-term expansion and growth for Vantage Goldfields lies in the Barbrook Mines Complex (BMC).

The BMC’s ore bodies are collectively deemed to be of sufficiently high grade and contain a substantial gold resource to provide the driving force for Vantage’s production expansion. The total JORC-compliant mineral resources (measured, indicated and inferred) for the known ore bodies is 14.52 Mt at 4.6 g/t. This implies total contained gold in the BMC’s mineral resources of just over 2.1 Moz. Small-scale production from the Taylors ore body within the BMC was initiated in May 2011. This is only the first stage of the company’s longer term production growth plans. The existing ore reserves at Taylors deliver between 7 000 and 10 000 ozpa of gold, which will be depleted at the end of 2013.

The proposed Barbrook Stage 2 expansion entails pushing the mine’s production over the 50 000 ozpa mark. This includes upgrading the status of mineral resources to ore reserves below the current 10 Level access adit at Taylors and determining the most viable processing option. “For now, we are cutting back on the Stage 2 bankable feasibility study to help preserve cash flow. It has, however, delivered great results thus far.”

Although the Barbrook ore bodies are recognised for their ‘double refractory’ nature, Vantage Goldfields has revealed that it may be able to leach the gold successfully without using the costly BIOX process. “This does not mean we are excluding the BIOX option, but are evaluating and testing other options as well,” McChesney points out.

The company has been evaluating process options ever since it terminated its off-take agreement to sell a high grade gold concentrate from Taylors to minerals trader, Mine2Market.

McChesney reveals that treating the concentrate through a direct carbon-in-leach (CIL) process is delivering satisfactory grade

which is making it extremely difficult for a recoveries. Upfront laboratory test work company of our size to raise money for its confirmed that it can successfully achieve expansion projects, the benefits of such an recoveries of about 60% through direct option is multi-tiered.” leaching of lower grade ores and as much as 75% on high grade ores. “Based on this, we BELOW Twin boom drilling rig in have recommissioned five redundant 20 m³ operation at Lily CIL tanks, which will leach the Taylors ore as BOTTOM Ian Moore (centre), the an entirely separate circuit. June represents metallurgical manager in charge of our first month of CIL production, which the direct CIL plant, together with if as successful as we predict will possibly his supervisors mark a major milestone in Barbrook’s future and possibly also the future of refractory ore processing.”

In addition to this breakthrough, McChesney believes there are options available that could improve leached recovery grades further. A Gold Fields licensed technology known as HiTeCC (high temperature caustic conditioning) – designed to strip gold from natural carbonaceous components in the ore before it is discarded as tails – was incorporated post bio-oxidation testing. This saw overall grades recovered in test work increase from 80% to 90%.

If further test work on the leaching process confirms that HiTECC can significantly increase overall recoveries at Barbrook, it is possible that the Stage 2 expansion could proceed Labour relations without the need to introVantage Goldfields has escaped the illegal strikes duce a BIOX pre-oxidation that have plagued the industry recently. “We step in the metallurgical dealt with this issue about three years ago, circuit. This would offer a and have developed a strong relationship with significantly lower capital AMCU, which represents 90% of our workforce,” McChesney reveals. cost option for expansion and a potentially simpler Vantage Goldfields has already signed its wage agreement for this year, which will be implemented flow sheet. from July, and does not anticipate any labour “Considering the current problems. The company employs about 600 people status of minerals reguand approximately 200 contractors. Most of its lations in South Africa, workforce is drawn from the local community.

INSID E M IN IN G 0 7 | 2013 27

PRECIOUS METALS

EVANDER GOLD MINE S

Earmarked for greatness A visit to Pan African Resources’ recently acquired Evander Gold Mines (EGM) leaves a single and lasting impression – unified commitment and dedication to extracting maximum value from an old lady who still has a lot to offer, writes Laura Cornish.

T

HE EGM acquisition has not only provided Pan African Resources (PAR) with an immediate production and revenue stream, but also a loyal, passionate and experienced team that is driven and committed to seeing EGM continue delivering on its steady production output and realise the The end of a shift. Returning to surface from underground at No 8 Shaft

28 I NS IDE MI NI NG 0 7 | 2 0 1 3

longer-term opportunities that the mine still has to offer.

Adding EGM to the PAR portfolio may be largely attributable to former CEO Jan Nelson, but his exit has by no means affected the current performance, or the short- or long-term future potential of the mine. The COO and interim CEO Ron Holding, together with the on-site management team, is fully invested in realising value from the operation and has already initiated a

number of internal growth projects that were on PAR’s radar even before the acquisition was finalised.

Maximising on EGM’s current potential EGM may have doubled PAR’s annual gold ounce output from 100 000 ozpa to about 200 000 ozpa, but this is by no means all that the mine has to offer. It mines the Kimberley Reef and based on current resource

PRECIOUS METALS

No 8 Shaft headgear

and reserve figures, it still has a 15-year lifespan. The Kinross process plant, situated just a stone’s throw from the single operating No 8 Shaft, has not been fully utilised for years, following the closure of numerous shafts, including 1, 2, 3, 5,

Despite its age, EGM still has some of the largest untapped resources and reserves in South Africa

COLLISION WARNING SYSTEMS INTRINSICALLY SAFE SOLUTIONS INDUSTRIAL NETWORKING, TELEMETRY, MONITORING AND CONTROL SOLUTIONS ENVIRONMENTAL SENSORING INSTRUMENTS ASSET MANAGEMENT AND SOLUTIONS

6, 7, 9 and 10 Shafts, within the EGM mining areas over the decades. It may be old, but it is still fully capable of delivering on its nameplate capacity of 240 000 tpm. According to the metallurgical manager, Thabang Hlalele, the plant is currently

THE MINING INDUSTRY TRUSTS BOOYCO ELECTRONICS TO PUT IT ALL TOGETHER! 0861 BOOYCO (0861 266926)

+2711 823 6842 • www.booyco-electronics.co.za INS I D E M I N I N G 0 7 | 2 0 1 3 29

PRECIOUS METALS

One of the large thickeners at the process plant

processing 40 000 tpm from 8 Shaft and another 20 000 tpm from old surface material.

Although EGM’s grade (about 7 g/t) is relatively stable, the general manager, Manny da Silva, indicates that the mine is expected to see a drop in grades as the mining plan takes it towards the edges of its gold-rich payshoot, but this is only temporary. Activity continues with Evander’s deepening project, which Harmony commenced in 2010 to gain access to high-grade areas below 24 Level. Part of the project also required significant upgrades to the shaft’s infrastructure – particularly with regards to cooling and ventilation, which has been completed.

The most immediate priority, however, is to offset the drop in grades. “For a start, we are aiming to deliver about 6 000 tpm at about 2.5 g/t from vamping old gold bearing rock at No 7 Shaft, situated adjacent to the process plant. The shaft comprises twin headgears where one is currently used to

of our 0.83 g/t surface sources for another two years,” he adds.

There is enough surface material to take the plant back up to its nameplate capacity and PAR is also evaluating the potential to process up to 200 000 tpm of slimes material. “We will target the higher grade dumps first. Our studies thus far indicate this particular project will average an expected recovered grade of about 0.17 g/t.”

transport underground 8 Shaft ore to surface. Vamping activity will take place at the unused men/material shaft. This is expected to start in July.

No 7 Shaft has the necessary infrastructure for mining in the old areas as well (pillar extraction etc.), and PAR is considering reopening some of these old mining The exciting long-term prospects sections. There is also the 2010 pay chanWhile steady-state production remains the nel to the north-east of 7 Shaft where the forefront priority, PAR is invested in unlockcompany needs to evaluate the position of ing EGM’s large and untapped potential, the reef, but this needs further exploration. which includes three new underground mines “We only want quality ounces and will only and a massive tailings retreatment project. pursue this project if it can meet our quality Despite its age – prospecting started in requirements,” says Holding. the area in 1903 Da Silva says – EGM still has that EGM is on some of the largthe brink of comest untapped pleting the converresources and resion of one of its serves in South self-grinding auAfrica.

Undertogenous mills to ground measured, a semi-autogenous INTERESTING indicated and inmill, which uses INFRASTRUCTURE ferred resources steel balls to delivConstruction of the Three Gorges Dam Wall in across the priority er a ‘finer’ grind.

China. The total duration of the project was identified areas “This will allow us 17 years and was carried out in three total 109.5 Mt or to extend the life phases starting in 1993 and ending in 2009 when 26 electricity producing turbo-generators were completed.

30 I NS IDE MI NI NG 0 7 | 2 0 1 3

PRECIOUS METALS

The EGM process plant (commissioned in 1967) • 12 silos; one in use with two feed belts (underground material and surface material) • 6 mills; two in operation • new cyanide plant • 5 heavy-duty thickeners ; two in use • hybrid carbon-in-leach and carbon-in-pulp circuits • two-column elution circuit – strip gold from carbon • smelter – gold sludge dispatched to Rand Refinery.

TOP Rock driller Kholisile Nkita MIDDLE The mill circuit BOTTOM No 7 twin shafts, situated adjacent to the process plant

28.7 Moz at about 8.16 g/t. Reserves currently equate to 39 Mt or 0.2 Moz at 8.2 g/t, excluding surface material.

Prior to his exit, Nelson spoke enthusiastically of what he considered to be one of the operation’s most exciting prospects, “which lies not in the mine itself, but in its tailings”. There is approximately 203 Mt or 1.9 Moz of tailings material on-site, which PAR has started evaluating internally. “We are aiming to make a decision on how to maximise on the potential opportunities the tailings may offer within the next 12 months. We have already redefined its purpose by changing its name from Harmony’s Mini Libra to the Evander Tailings Reclamation Project. We believe a plant capable of processing around 1 Mtpm at a grade of no more than 0.4 g/t is a definite possibility,” he said.

Rolspruit, an extension of No 8 Shaft situated to the north, is an attractive prospect.

Based on historical records, the area has significant resources (25.5 Mt at 10.89 g/t for 8.9 Moz) and reserves (23 Mt at 8.29 g/t for 6.2 Moz) at high grades. This is high enough to warrant the construction of its own vertical shaft, although PAR wouldn’t fund the sinking of a shaft to Rolspruit alone.

Evander South and Poplar, which lie to the west and north-west of No 8 Shaft, would also require new shafts and process plants, and probably a joint venture funding partner. A completed drilling programme at Poplar indicates the 34.9 Mt resources lies at depths of between 500 and 1 300 m.

It would average about 6 g/t for 7 Moz. A completed drilling programme at Evander South indicates the 29.8 Mt resource lies at depths of between 250 and 1 200 m at grades of about 6.1 Moz.

INSID E M IN IN G 0 7 | 2013 31

PRECIOUS METALS

GO LDP L AT

Ghana and SA refocused AIM-listed African-focused gold producer Goldplat has restrategised its business with the aim of generating cash from its mines in South Africa and Ghana, and is placing its Kenyan operation on care and maintenance.

I

N ORDER TO eliminate losses caused by continued operational constraints and the current uncertain gold price environment, Goldplat has put its Kilimapesa gold mine (KGM) in Kenya on a care and maintenance programme until the project economics can justify its reopening.

KGM has retrenched 50 employees and is now maintaining the mining operation on a skeleton staff. The processing plant will continue to process stockpiles of ore at the plant to cover the costs of the care and maintenance programme.

In terms of the company’s gold recovery operations,

African operation, which secures waste products predominantly from blue chip mining customers.

Due to the continued margin pressures sustained primarily from purchasing materials from artisanal and small-scale miners, Goldplat has stopped procurement of material for GRG’s carbon-in-leach (CIL) plant and is in the process of temporarily closing this section down. It will remain closed until material that meets the company’s margin criteria is sourced on a sustainable basis.

However, GRG continues to procure material to supply the Nzema mine in Ghana as per its tolling agreement that processes tailings off-site with Endeavour Resources.

On a wider level, the incinerator section, which processes fine carbon from the major gold producers, is operating well – notwithstanding the refractory failure in one of the fluidised bed inGPL in a nutshell cinerators, which is currently GPL’s technology provides an being recommissioned. economic method for mines to As a result of the above dispose of waste materials while at the same time adhering to a mine’s and the continued low gold environmental obligations. Its blueprice, Goldplat’s board has chip supplier base includes AngloGold advised that EBITDA for the Ashanti, Goldfields, Harmony 2013 financial year is likely and Lonmin. to be materially lower than which recover gold market expectations. from waste prodThe company’s South African gold reucts of the gold covery operation, Gold Recovery Limited mining process, (GPL), continues to produce a strong cashGoldplat has also flow, with particular emphasis on fine carcompleted a review bon processing. The processing has expandof Gold Recovery ed significantly over the past six months Ghana (GRG), its with new supply contracts recently signed Ghanaian operawith major South African gold producers. tion in Tema. FolThe company operates from a 22 ha freelowing this process, hold site based near Benoni in Gauteng, near the company is the centre of the East Rand Goldfield. After looking to refocus testing to establish assay, moisture content, its recovery modrecoverability and size, GPL purchases the el to replicate its materials from the mine operator. successful South Goldplat Recovery’s extraction processes and multiple process lines enable it to keep materials separate, which provides a A gold pour high degree of flexibility when proposing at GPL

INSID E M IN IN G 0 7 | 2013 33

PRECIOUS METALS

a solution for a particular type of material.

The processes used include roasting in a rotary kiln, crushing, milling, thickening, flotation, gravity concentrators, leaching, CIL, elution and smelting of bullion.

Production is scheduled to make the most efficient use of the materials, taking into account the ore grade and anticipated recovery factors. Raw materials are blended and routed to the various plants in an effort to ensure that production levels are reasonably consistent from month to month. In

some cases, simikiln, which is still lar material can be on target to be treated in different commissioned in INTERESTING INFRASTRUCTURE July 2013. plants. The wide variety of mate“The strategic The Banpo Bridge in South Korea – an amazing infrastructural achievement. rials stockpiled review launched means that it can when I took over benefit from being able to blend materials the role of CEO in September 2012 is fofor more effective processing. cused on creating long-term sustainable valNew capital projects are also under way to ue for shareholders while continuing to gencontinue increasing gold recovery producerate cash. It is always disappointing to sustion including the recent commissioning pend any operation, but it is of paramount (March 2013) of an importance that we make sure that all our additional tailings reoperations are profitable and do not repretreatment CIL plant, sent a drain on the resources of the rest of which will help prothe company. With regards to Kilimapesa, cess five years’ worth we will continue to assess the viability of of tailings on-site, as the operation and engage with all the stakewell as the purchase holders, including the local community and of a second rotary the Kenyan government, to map the way forward. In Ghana, GRG will look for alternative sources of CIL material that meet our New tailings margin criteria and continue discussions rereatment carbonwith the gold majors to build the traditionin-leach plant al recovery business in West Africa,” says installed at GPL in March 2013 Goldplat’s CEO, Russell Lamming.

34 I NS IDE MI NI NG 0 7 | 2 0 1 3

Urethane

|

Wear Linings

|

Site Services

|

Steel Fabrication

|

Engineering

Engineering South African-based manufacturing company UMP provides specialist polyurethane and engineering services to clients operating in the mining, infrastructure and engineering industries.

•

General engineering Specialised fabrication

•

Automotive components

•

Polyurethane incorporated machining

•

14 Plantation Rd, Edenvale, Gauteng, South Africa Tel: + 27 11 452-1000 | Fax: +27 11 609-6477 www.ump.co.za

NGAGE EVERYONE UMP-P-02

Engineering services include:

%>OABKFKD «LLOP >KA J>HFKD QEBJ PEFKB HUSQVARNA PG 820 12.5 kW - 17 hp - 380 - 480 V - 3 phase - grinding width 820 mm - 440 kg

Cif gifZUWY dfYdUfUh]cb UbX Xigh Wc``YWh]cb gmghYag WfYUhY Ãccfg k]h\ aU[b]ÂWYbh dfcdYfh]Yg" H\Y <igejUfbU D; ,&$ ]g h\Y `Uf[Ygh ]b h\Y fUb[Y cZ gifZUWY dfYdUfUh]cb UbX Âb]g\]b[ aUW\]bYg" 9ei]ddYX k]h\ 8iU` 8f]jY HYW\bc`c[m h\Y D; ,&$ ]g Uacb[ h\Y aUf_Yh»g acgh dckYfZi` UbX YZÂW]Ybh aUW\]bYg" K\UhYjYf `YjY` cZ Âb]g\ mci UfY `cc_]b[ Zcf kY \UjY X]UacbX hcc`g Zcf acgh aUhYf]U`g"

HUSQVARNA DC 5500 5.5 kW - 380 - 480 V - 3 phase - 5 pin - 16 A - vacuum max 300 m bar - 215 kg

The Husqvarna DC 5500 has exceptional performance and industrial strength to aYYh YjYb h\Y acgh XYaUbX]b[ ]bXighf]U` Udd`]WUh]cb k\YfY \][\ giWh]cb UbX Ãck UfY required, to eliminate airborne dust. This highly mobile and versatile unit can be used for both wet and dry applications coupled with the Husqvarna PG 820.

HUSQVARNA CONSTRUCTION PRODUCTS

www.husqvarnacp.co.za G\UfY 7U``. $,*$$ (,+)-" HY`. $'' ,(* -+$$" ]bZc4\igejUfbU"Wc"nU <igejUfbU ]g U fY[]ghYfYX hfUXYaUf_" 7cdmf][\h &$%' <IGEJ5FB5" 5`` f][\hg fYgYfjYX"

September 18 -21 Gallagher Convention Centre Johannesburg

MEET. CONNECT. EXPAND.

AFRICA’S PREMIER CONSTRUCTION AND MINING SHOW more than 500 exhibitors over 60 000 square metres of exhibition space G E RE N I L ON r FOR E C giste N e A r / R T .com E EN rica f a FRE ma .bau w w w

IS

TION TRA

S!

INTERNATIONAL TRADE FAIR FOR CONSTRUCTION MACHINERY, BUILDING MATERIAL MACHINES, MINING MACHINES AND CONSTRUCTION VEHICLES

www.bauma-africa.com

CONTENTS

Infrastructure in Africa P38

The key to future growth is infrastructure

The best way for African countries to get more value from mining is to leverage the related infrastructure more effectively, so that the local and national economies can broaden their foundations into non-mineral sectors. By Peter Labrum, MD of SRK Consulting SA.

P50

Introducing the AAD Group

Intent on aligning itself more closely with the needs of the medium and heavy automotive sector, D&A Power Products has changed its name to Associated Automotive Distributors.

P52

Bypassing unreliable transmission lines

African satellite communication solutions provider Telstream Telecoms has launched a number of new satellite services this year that have drastically reduced satellite bandwidth costs, allowing remote mine sites to stay connected while bypassing unreliable local infrastructure.

P40

Developing a road to business sustainability

Hatch’s strategy to develop a growing and sustainable business has been cemented thanks to its acquisition of Goba earlier this year. The newly formed entity, Hatch Goba, now boasts infrastructure expertise – the perfect supplement to its multi-disciplinary suite of mining and energy skills.

P42

P54

Upper-class development for Kathu miners As main contractor on the Bestwood Estate project in Kathu, Northern Cape, Esorfranki Civils is on schedule to complete all civils works on this new mixed-use human settlement development by the third quarter of 2013.

Impressive infrastructure insight

African minerals processing plant specialist Consulmet is proving that the key to successful infrastructure development in Africa is realistic acknowledgement and understanding of challenges and scenarios likely to be encountered, says director Wildu Mostert.

P45

The roles of mines and government

Monitor Deloitte director Andrew Lane gives his view on where mining companies must draw the line in fulfilling government’s basic role of supplying infrastructure such as rural housing, clinics and schools for mining communities.

P46

Ripe with infrastructure opportunities

The CEO of internationally recognised consultancy firm SMEC South Africa, Dr Thomas Marshall, says that having already established a strong foothold in Southern and East Africa, SMEC is looking to further expand its presence in West and North Africa.

P48

P56

Extractive industries reap the benefits

Extractive industries are major users of fresh water, but are also direct and indirect producers of wastewater.

Because these industries are critical to the continuous development and growth of the African economies, sustainable and responsible growth as well as costeffective and flexible water management, treatment, reclamation and reuse infrastructure are required.

P58

Spot-on mining solution

Flotation solutions provider DockPro, established in 2010, may have initially targeted the leisure market, but has quickly realised the attraction its product range offers the mining industry, says MD Rob Clarke.

The signs are there

Mining companies’ demand for geospatial information in Africa has increased over the years as they seek to develop infrastructure that will integrate well into their business models and improve productivity, says Southern Mapping CEO Norman Banks.

P60

On track for UMK

SBS Water Systems is proud to be working in association with Aecom on the manufacture, supply and installation of an SBS Tank to the UMK manganese mine near Hotazel in the Northern Cape.

INSID E M IN IN G 0 7 | 2013 37

INFRASTRUCTURE IN AFRICA

C HER IS H A FRICA

Infrastructure is the key to future growth

I

T IS ALWAYS heartening to be involved in mineral projects around Africa, as the economic spin-off generally gives a boost to both the local economy and the host country’s state revenues. SRK’s involvement is usually on the mining side, but just as often extends to the infrastructural elements of these projects – including roads, rail, ports and water supply.

Indeed, mining operations usually require a range of infrastructure before they can be viable. Where these facilities exist, they will need to be improved and/or extended to cater for the mine’s needs; where they don’t exist, the mine often has to take the lead in building them from scratch.

This creates huge opportunities for host economies, as the mine provides a valuable ‘kick-start’ to economic activity – especially in remote or previously under-serviced areas.

It hardly needs stating that the building of infrastructure – be it roads, rail lines, electricity supply or water pipes – is an expensive capital investment. So it deserves the best possible planning, implementation and maintenance.

Good planning of infrastructure ensures that it can be leveraged widely – not just optimising the operation of the mine it has been built for, but also fostering other

felt by local people, and they therefore need to be engaged and consulted when interventions are made that affect them.

Finally, and crucially, there are the demands of good maintenance. Given the high capital costs of infrastructure development, there needs to be far more emphasis placed on maintaining these costly resources. This is not just a matter for a project or a particular scheme; it highlights what should be a central tenet of national development: to accumulate infrastructure over time, rather than get into the habit of having to replace what has stopped working.

As engineering consultants that offer a variety of solutions for sustainable development, our experience is clearly that much of the infrastructure around the continent does not last as long as it should. And this severely undermines our ability to build a developmental highway to the future.

The more constructive approach – now evident in those regions of Africa that have been more successful in building modern economies – is to progressively add to the levels of infrastructure over time, while maintaining the effectiveness of previous generations of public facilities.

The best way for African countries to get more value from mining is to leverage the related infrastructure more effectively, so that the local and national economies can broaden their foundations into non-mineral sectors. By Peter Labrum, MD of SRK Consulting SA.

38 I NS IDE MI NI NG 0 7 | 2 0 1 3

Mining operations usually require a range of infrastructure before they are deemed viable

economic opportunities in the vicinity and beyond. Such planning requires good governance in the political sphere, as local, regional and perhaps even national government could be involved.

Successful implementation of the plan requires effective project management, backed by solid engineering skills that ensure the resulting facilities are fit for purpose. It should also be remembered that infrastructure is not just a technical matter; the benefits of these facilities are

INFRASTRUCTURE IN AFRICA

Only recently, South Africa’s deputy presiunfortunate that coal from the northern therefore needs to be carefully coordinated dent, Kgalema Motlanthe, told the annual provinces was transported via trucks beto avoid imbalances in the way that public convention of the Road Freight Association cause there was a lack of rail infrastructure. facilities are used and to ensure that they that South Africa He said the remake the economy more efficient. Only by needed to increase sult was clear: the regularly maintaining the continent’s exits use of rail lifespan of main tensive infrastructural investments can we freight to boost and arterial roads effectively build upon them. New business economic growth – not designed can then thrive, supported by affordable and preserve the for such heavypublic services that make them efficient country’s roads. freight movement and competitive.

This comes in the – was decreased The National Development Plan’s recomINTERESTING context of the significantly mendation for South Africa is equally appliINFRASTRUCTURE and the mainteNational Developcable to the continent as a whole: we need ment Plan’s comnance schedules to maintain and expand the electricity, The Atlantic Road is an 8-km long stretch of road between the towns of Kristiansund and ment that South were disrupted.Inwater, transport and telecommunications Molde, the two main population centres in the Africa’s rail sector frastructure planinfrastructure in order to support economcounty of Møre og Romsdal in Norway. performs “signing at all levels ic growth and social development goals. nificantly worse” than in comparable nations and needs to Peter Labrum, MD for SRK Consulting (SA), has over 37 years’ experience be maintained and expanded. in civil and structural engineering and project management. He has been with SRK for 25 years.

He reinforced the widely held view that His expertise includes design of water treatment and water supply long-haul cargo, such as coal and iron ore, infrastructure and dams, bridge design, general civil and structural should exclusively be transported on rail design of mine infrastructure, project management and contract administration, and mine closure cost estimates. instead of the road networks and said it was

INSID E M IN IN G 0 7 | 2013 39

Geology solution independent Iterative design process Fantastic graphics performance

Interactive scheduling with EPS Visualize, Animate with EPS Viz SpatialDBTM Exchange-Ready

The new Mine2-4D combines with EPS to form a complete mine planning and scheduling system that delivers cost and performance improvements like no other solution. Along with MineRP’s Spatial Database, Mine2-4D delivers unrivalled data management and integration capabilities.

INFRASTRUCTURE IN AFRICA

H ATCH GOBA

Developing a road to sustainability Hatch’s strategy to develop a growing and sustainable business has been cemented thanks to its merger with Goba earlier this year. The new Hatch Goba, now boasts infrastructure expertise – the perfect supplement to its multidisciplinary suite of mining and energy skills, writes Laura Cornish.

T

HE GLOBAL HATCH business strategy has always been focused on sustainability and the ongoing need to expand and diversify to ensure such sustainability,” says Hatch Goba’s MD, Rory Kirk. “This means broadening our horizons in terms of skills and capabilities.”

Globally, Hatch is well-known for its mining and metals as well as its energy engineering competencies. Merging with Goba has provided the company with immediate infrastructure strengths and a long-standing infrastructure legacy. Its

infrastructure, coupled with Hatch’s minerals strengths, has resulted in a new entity with complementary skill sets, a widespread African footprint and an expanded client base – all geared towards ensuring business sustainability.

The Goba merger, which started in 2011 and was concluded recently, is one of Hatch’s largest to date and has seen local employee head count increase to 1 500, but Kirk says it has and will not affect the company’s nimble and flexible business approach.

Coming together

“The necessity for infrastructure in Africa continues to play a pivotal role in the future of our business.” Rory Kirk, managing director of Hatch Goba reputation for delivery of major roads, highways, airports and bridges; water and wastewater; and mining and industrial

40 I NS IDE MI NI NG 0 7 | 2 0 1 3

The relationship between Hatch and Goba extends back to the companies’ first joint venture project, which formed part of Transnet’s capital expansion programme. The relationship between the two companies further solidified over the years thanks to numerous projects

that Hatch and Goba worked on together, and is a definite contributor to what can be described as a seamless merger.

“We also wanted to ensure that the knowledge we had gained from the Transnet project, with regards to infrastructure, was not lost. Particularly as the necessity for infrastructure across the African continent continues to play a pivotal role in the future of our business,” Kirk continues.

“Bringing Goba’s knowledge and skills into the business will ensure this.”

Hatch Goba’s chairman, Trueman Goba, adds: “For the public sector in South Africa, Hatch Goba is now able to offer a differentiated service to clients who want to implement the priorities that are highlighted in the National Planning Commission and the National Development Plan, and are key to South Africa’s economic growth.”

Public infrastructure opportunities are also opening up in Africa and, in many cases, are linked to the development of new mines. Hatch Goba offers potential ABOVE Hatch Goba will focus on infrastructure opportunities for the mining sector in South Africa BELOW Goba is well recognised for its local infrastructure capabilities

INFRASTRUCTURE IN AFRICA

customers the full package: mine and plant development and the necessary associated infrastructure, which in Africa is sorely needed and is key to project viability.

“As a company, we will continue to promote our ability to deliver a differentiated service – especially in terms of engineering complexities. We overcame some complex challenges on the Transnet job and will use this project as a case study to promote and highlight this particular strength,” Goba says. Kirk feels Hatch Goba’s well embedded employee safety culture is another business differentiator. “Our safety culture will permeate throughout the new company.”

Moving forward “Although the merger was only finalised in March this year, we have been cooperating on various projects. My primary role is to prevent silos from developing and ensure a co-ownership project approach. Ensuring all Hatch Goba personnel are situated under ‘one roof’ encourages this,” Kirk points out. “And the feedback from the industry

has been positive and our clients feel it ‘makes great sense’.” All contracts awarded to both companies prior to the merger are continuing forward under the new entity name.

Hatch Goba’s targeted objective to obtain a minimum Level 3 contributor status in terms of the current BBBEE codes will be driven by an active BBBEE strategy to ensure that it contributes positively to transformation within its sector and to society as a whole.

“Having worked together on a number of projects over the past six years, Hatch and Goba have developed a strong relationship with a good cultural fit. We will continue to give priority to developmental programmes and career opportunities for our employees. What’s more, ongoing investment in developing local employees will ensure that the specialist skills base in both engineering and large-scale project delivery, which is greatly needed in South Africa, continues to grow,” Kirk outlines.

Retaining the Goba brand name was a strategic decision, Kirk mentions. “Keeping

the Goba name shows respect for Trueman, who will be instrumental in introducing the Hatch business to new areas. He also has a great relationship with government.

“It has been a journey that has been travelled with vision, integrity, fairness and excitement, and we look forward to what the future holds. We are committed to supporting the development and implementation of efficient projects, which Southern Africa needs in order to grow the economy. What’s more, our mission is to bring ‘smart’ solutions to our clients by bringing broader skills and global experience to the fore,” concludes Kirk.

Hatch Goba clients • Richards Bay Minerals • Anglo American Thermal Coal • First Quantum Minerals (Tenke Fungurume) • Mopani Copper Mines • De Beers Consolidated Mines • Impala Platinum • Anglo American Platinum • Sasol Mining

INSID E M IN IN G 0 7 | 2013 41

INFRASTRUCTURE IN AFRICA

C ONS U LME T

Impressive infrastructure insight African minerals processing plant specialist Consulmet is proving that the key to successful infrastructure development in Africa is realistic acknowledgement and understanding of challenges and scenarios likely to be encountered, director Wildu Mostert tells Laura Cornish.

C

ONSULMET IS A specialist in designing, delivering and building process plants in remote African locations and is familiar with the challenges working in Africa brings. This makes the company an ideal candidate for mining infrastructure development. “The combination of our working experience outside of South Africa and our client relationship network has enabled us to capitalise on developing a new internal business section, generating additional cash from broadening our project scope beyond process plants,” Mostert outlines.

Depending on the required scope, infrastructure, on average, forms up to 50% of a new mining project’s value and is an essential component to any new start-up venture in Africa, in part determining overall viability. “Because we are so close to the projects we work on, we have a true understanding of the individual infrastructure requirements a project needs. It is this recognition that led to the establishment of a division dedicated to providing our clients with infrastructure that is tailor-made to suit logistical constraints and on-site conditions on a lumpsum turnkey basis. In Africa, consolidated service offering is the key to success,” Mostert continues.

42 I NS IDE MI NI NG 0 7 | 2 0 1 3

be selling process Today, ConsulINTERESTING met Infrastructure INFRASTRUCTURE plants. By incorporating infraemploys specialOn 26 June 1860, the first steam train in South structure into our ists in the fields of Africa made its first official journey between Durban and the Point. The distance of the contract we can civil engineering, railway line was only 3.2 km, and the ‘control our own commercial conjourney is said to have taken only five minutes. destiny’. The key struction, housing, to getting it right roads, drainage, starts with strong on- and off-site managestormwater, slimes dams, electrical inframent, a dedicated site team, a qualified and structure, diesel and fuel plants/yards and experienced procurement department, realstructural civil construction. The division istic challenge expectations, scenario planand associates are responsible for the archining for every possible incident and contectural designs, geotechnical reports, civil stant communication between site and head designs, structural designs, engineer’s deoffice,” Mostert explains. signs, construction, installation and impleFast project turnaround time, flexibility to mentation of these fields. adapt and change if and when necessary and The division’s aim is to provide mining a flat management structure that enables infrastructure that is cost effective, susquick decision-making are equally importtainable, environment-friendly and safe. ant, in addition to understanding weather “We were intimidated by the challenge of patterns and conditions, the environment, engaging infrastructure implimentation, skills levels and raw materials (availability but recognised the rewards we could reap if and quality). successful. We tackled our upfront concerns “Of course logistics is crucial. Delivering and planned for every possible eventuality.” plant and infrastructure equipment to site

The key components “Consulmet’s core business focus will always

INFRASTRUCTURE IN AFRICA

requires in-depth surveys of road quality or lack thereof. Such a simple element influences our design and equipment component choices. Load weight and distribution are carefully considered to ensure our plant stays intact on its journey to site. So who better to customised fit-for-purpose designs, than the company that travels these same roads so often?”

The strategy

project also included electrical reticulation, power station and generation (10 MW); a fuel depot for both heavy (mining) and light vehicles, including specialised fuel filtration; town planning; water treatment plants, including reticulation; and sewage treatment plants including reticulation.

ALL PICTURES Consulmet is capable of providing all infrastructure requirements in Africa

All structures were constructed and erected using sustainable development methods and procedures. The majority of basic raw materials used were local materials from Sierra Leone.

Apart from the commercial buildings, diesel, water and electrical infrastructure, Consulmet Infrastructure also undertook to construct lodge-like housing for the accommodation of senior expatriates, including a mess/entertainment facility.

Consulmet has managed the civils implementation on-site for all of its projects since its inception and will continue to do so through its new division. For now, its infrastructure work is generated through process plant contracts and the facilitation of the structural concrete requirements for the processing plants remains the core functions of this division. This has seen its division already successful across Africa in countries including South Africa, Zimbabwe, Botswana, the DRC, Sierra Leone, Australia and Angola.

“Our long-term strategy is to grow and expand our infrastructure division into areas outside the current core function of structural concrete for the process plants,” Mostert notes.

Consulmet Infrastructure’s first project The division’s most diversified project was the provision of infrastructure for the Koidu kimberlite mining operation in the rural Kono District of Sierra Leone. This project was undertaken as part of the whole Koidu development and consisted of 29 different types of buildings.

These included workshops, stores, access buildings, offices, emulsion building, staff change houses, a clinic, incinerator buildings, security buildings and offices. The

INSID E M IN IN G 0 7 | 2013 43

INFRASTRUCTURE IN AFRICA

LOC AL MINING NE E DS

The roles of mines and government Monitor Deloitte director Andrew Lane gives his view on where mining companies must draw the line in fulfilling government’s basic role of supplying infrastructure such as rural housing, clinics and schools for mining communities.

I

THINK THE topic is indicative of the situation we find ourselves in in the mining industry. It is indicative of a slightly tense relationship when people talk about drawing lines and I don’t think it’s that simple,” he starts.

According to Lane, government is spending a lot of money on education, health and human settlements ‒ almost R300 billion in the past 12 months. “So government is putting in the effort. Access to water and electricity has improved as well as unemployment – marginally. But many South Africans still feel underserved” The mining industry also spends on social investment, he continues. “The top nine mining companies listed on the JSE spent about R3.5 billion in the past 12 months on corporate social initiatives (CSI).” So what then is the underlying problem?

“If you ask the mines what they think is important in terms of their communities’ needs, they have made the link to some of the root problems – education, education development, enterprise development, etc. But they are spending their money on the shortterm needs of the people that live ‘right outside the gate’, which means to some extent they are taking on the role of government.

Rankings of perceptions, however, remain very different between communities, government and mines on spending in the right areas, which means they are not getting the results everyone is looking for.” So what’s the answer?

“We are all in the same boat and it has to stay afloat. The problem is that CSI is a very compliance-driven mindset. We do it because we have to. We have a scorecard and mining charter to comply with so we tick boxes, but don’t give too much thought to what we are doing, and that leads to a lot of leakage in value. Remember, CSI is an investment into a system that has to live and work together. When we want to invest in something that will benefit the community outside the gate, there can be a return. There is value in the fact that our people don’t get killed on their way to work in the morning, that they sleep well and are well fed.

Lane outlines three parameters that could change the dynamic between the mines, government and communities.

We need to start measuring social impact.

“How do you ensure that money invested results in real social impact and translate this into a number that a government or community representative across the table understands?

If we get the facts in the room and have a fact-based conversation – where the money is going, what impact it is making – the relationship between our stakeholders will become a bit easier to manage. Then we can start to have a constructive debate.”

We need to engage effectively with all stakeholders. “We are all telling everybody else what to do and we are not looking back at ourselves and saying what should we do.

The stakeholder environment is complex and there are a lot of hidden agendas that are not understood. It is difficult to respond to a situation that you don’t fully understand.

We could have more productive debate if we engaged more effectively.”

Inclusive solutions – how do you include

“When we want to invest in something that will benefit the community outside the gate, there can be a return” poor people in the major value chains of the economy? Africa is a smallholding agricultural continent. ”We need to include poor people as economically active members, either as customers or suppliers. A lot of enterprise developments are targeted towards that.”

In a nutshell, Lane says there needs to be a way of measuring social impact and define it in a way that all stakeholders and participants, including the government and the community, can understand.

TOP The mining industry has invested billions in local infrastructure for their employees. Seraleng housing project in Rustenburg (2012). Picture courtesy of Anglo American. Photographer: Geoff Brown

INSID E M IN IN G 0 7 | 2013 45

INFRASTRUCTURE IN AFRICA

WES T AND NORTH A FR IC A

Ripe with infrastructure opportunities D Thomas Marshall, Dr CEO of consultancy C firm SMEC South Africa, says the A company is looking tto further expand its presence in West and p North Africa, having No already established alre strong foothold a st iin Southern and East Africa.

M

AIN MARKET indices in countries such as Nigeria and Kenya have risen by more than 50% in the past year and investor confidence in Africa is rising at a rapid rate. Marshall believes these events could be the key to growth for the company, especially in West and North Africa.

“Within West Africa, where we are currently operating in a limited number of countries, we are focusing our expansion plans on mining-related and developmental infrastructure projects, while in North Africa we are targeting transport infrastructure, water and power-related projects. Countries such as Libya, Algeria and Morocco hold a vast amount of potential when it comes to structural development and reconstruction,” explains Marshall.

Since VelaVKE’s merger with the SMEC Group in June 2012, SMEC South Africa has also become involved in a number of projects across the traditional SMEC footprint with both private and public sector clients.

“Being part of the larger SMEC group

With the addition of GMC Global, SMEC’s mining consultancy and management capabilities will be substantially improved

has allowed us access to greater resources and a larger skills base for servicing African clients, but also enables us to service new geographic market areas within other growth regions. An example would be our large bridge design capacity – we have become one of South Africa’s biggest large bridge design companies with engineers currently working on prestigious bridge-related projects in Asia, as well as on proposals for bridge-related projects in Australia,” explains Marshall.

“Being part of the larger SMEC group has allowed us access to greater resources and a larger skills base for servicing African clients”

46 I NS IDE MI NI NG 0 7 | 2 0 1 3

INFRASTRUCTURE IN AFRICA

Gauteng south office SMEC head David Gertzen points out that the SMEC Group’s acquisition of GMC Global – an internationally recognised leader in the productivity improvements, cost control and infrastructure management services to the mining industry – will be a large focus for the company going forward.

With the addition of GMC Global, SMEC’s mining consultancy and management capabilities will be substantially improved, says Gertzen. Combining the expertise and experience of both companies will prove to be highly beneficial to clients in Africa.

“GMC, which improves productivity and cost control at mines, joined the SMEC Group in January last year. For the next two years, we plan to focus on rolling out GMC Global’s services and products in Africa, which are aimed at assisting clients in establishing and executing visions and strategies, as well as supporting leadership capabilities

and enhancing technical skills through people, processes and skills,” explains Gertzen.

He says GMC’s history of enterprise planning and development, paired with experienced consultants, has benefited the mining sector in over 115 productivity projects worldwide. The GMC Global

SMEC is targeting West and North Africa as potential growth areas for the company

consultants have an in-depth understanding of a mine’s operations and have handson experience in operational productivity improvement.

INSID E M IN IN G 0 7 | 2013 47

Local People. Global Experience.

SMEC Mining, Oil & Gas assists clients with establishing and executing vision and strategies, supporting leadership capabilities and enhancing technical skills to deliver optimal and sustainable results.

As owner’s representative and project managers we also provide our clients with cost effective, comprehensive and innovative solutions.

Our key leaders and staff, on average, have 20-plus years mining industry experience, gained by working in many of the leading mining and consulting organizations.

SMEC Mining, Oil & Gas capabilities include: • Operational improvements and cost control • Optimal mining infrastructure design • Mining risk management advice • Mining technology and process advice • Project management • Owner’s representative solutions.

For further information contact Mr Gerrit Brits on 011-369 0600 or johannesburg@smec.com

INFRASTRUCTURE IN AFRICA

AFRICA N DE VE LOPM E N T

The signs are there

Mining companies’ demand for geospatial information in Africa has increased over the years as they seek to develop infrastructure that will integrate well into their business models and improve productivity, Southern Mapping CEO, Norman Banks, tells Reggie Sikhakhane.

T

HE COMPANY, which provides geospatial data to companies from various sources such as satellite and airborne platforms, reveals that mining companies, particularly those that are active in sub-Saharan and West Africa, have shown an interest in infrastructure development in their respective regions.

“Africa is a continent with vast resources, yet it is underdeveloped when it comes to infrastructure. We have seen companies, as well as governments, taking initiative in terms of infrastructure development through the realisation of the importance that it can play,” explains Banks.

He says that Southern Mapping is appointed by mining houses to cater to different demands. “Through our aerial surveying and satellite imagery capabilities we are able to provide contour plans for resource estimation and infrastructure design, and through optical imagery we are able to collect social and environmental information.”

48 I NS IDE MI NI NG 0 7 | 2 0 1 3

Optical imagery helps Southern Mapping determine where roads can and cannot be built, as the imagery from this platform provides information on the geological condition as well as any human settlement and vegetation species.

Further, through thermal imagery, Southern Mapping is able to identify any underground coal fires or groundwater.

ALL PICTURES Through aerial surveying and satellite imagery capabilities, Southern Mapping is able to provide contour plans for resource estimation and infrastructure design

“We have completed many infrastructure planning projects, especially for long linear features such as roads, rail, powerand pipelines.”

Across Africa Southern MapBanks notes that ping highlights the company has that it has done established a footclose to 3 000 km print across Africa of route surveyINTERESTING through some of INFRASTRUCTURE ing for railway the projects that lines, which are to The 280 m long Helix Bridge is a it has completed, link the province pedestrian bridge linking Marina Centre which include surof Tete in Mowith Marina South in the Marina Bay area veys for power line zambique to the in Singapore. design for mining country’s coast to companies and government, route selection ease transportation of coal. “We have done for both road and rail, as well as dam design. extensive route surveying in Mozambique,

INFRASTRUCTURE IN AFRICA

both for existing and new railway routes,” adds Banks.

In most cases regarding infrastructure development, Banks says a mining company will be located far from the coast and will need a way to get its product onto ships for export. “We are seeing more mining companies that are situated inland looking to either upgrade, or start from scratch, a port facility. We have been able to complete both these demands, more recently for Sundance Resources, which has iron ore assets in Cameroon and the Republic of the Congo.”

The company has also done surveying for companies such as diversified miner Rio Tinto and Brazil-based Vale.

“We are seeing institutions such as the African Development Bank become more open to infrastructure development-related funding, and where governments are lacking in initiative, private companies seem to be taking on responsibility to develop infrastructure,” he says.

Challenges Southern Mapping’s CEO admits that

undertaking projects in Central and West Africa is challenging. “Weather is a major factor, especially in Central Africa. The cloud cover is low in terms of height above ground, which forces us to fly lower, resulting in us having to cover more ground space, translating to more fuel.

“Also, the cloud coverage is so bad at times that we are forced to wait for the clouds to clear, as they interfere with imagery quality,” he explains.

for companies like Anglo American, Kumba Iron Ore and BECSA.” Further, he says the company has been awarded contracts for the design of dams in Tanzania, and the Republic of the Congo, while Namibia’s power utility, NamPower, has appointed the company to survey a power line route.

Outlook Banks reveals that there are a number of projects in the pipeline for Southern Mapping, noting that many mining projects are in South Africa.

“We will be busy with mine and infrastructure development and resource estimation projects in South Africa

INSID E M IN IN G 0 7 | 2013 49

ADVERTORIAL

NEW AND IMPROVE D

Meet the AAD Group Intent on aligning itself more closely with the needs of the medium and heavy automotive sector, D&A Power Products has changed its name to Associated Automotive Distributors (AAD).

N

OW KNOWN AS the AAD Group of Companies, it is configured for greater productivity and efficiencies while ensuring customers gain increased awareness of the group’s broad product offerings. “In recent years, the automotive sector has seen sharp rises in the costs of its applications,” says AAD’s CEO, John Lachenicht.

“Operational efficiency is thus paramount in the drive to manage the lifetime cost of ownership. The AAD Group will help

50 I NS IDE MI NI NG 0 7 | 2 0 1 3

customers achieve these efficiencies by simplifying the supply chain and building on its one-stop-shop philosophy through its product offerings on a national basis.”

“The new-look centres around the creation of complementary subsidiaries, each with its own specialisation and rapid decision-making,” adds Lachenicht. “In addition to its OEM franchises, AAD provides lifetime service, components and parts to keep vehicles in perfect running order and minimise downtime. The majority of

our 400+ people are long-serving, with the experience, customer-focus and product knowledge to ensure we deliver value over the long term.” Since taking over the assets of Leyland South Africa in 1987, the group has grown the business and established a broader national footprint. The restructured AAD operates in clearly defined pillars.

AAD Specialised Transport Solutions, part of the waste management pillar of the restructure, is the exclusive sub-Saharan Africa distributor for Dulevo products.

1THREAD_4139_INS

Geared Motors \ Drive Electronics \ Drive Automation \ Industrial Gears \ Services

We drive the mining industry

SEW-EURODRIVE offers innovative drive solutions for all applications in the mining industries.

All SEW-EURODRIVE products and systems make the best use of the space available around the machine and ensure great ďŹ&#x201A;exibility and reliability. Minimum maintenance and simple operation ensure that you will operate machines and equipment efďŹ ciently from the very beginning.

Thanks to the modular design and countless combination options, all drive engineering components can be replaced quickly, if the need arises. From gravel mining to the excavation of gold, platinum, coal and diamonds - we put the drive into all facets of the mining industry.

SEW-EURODRIVE - Driving the world.

Tel: +27 11 248-7000 Web: www.sew.co.za

INFRASTRUCTURE IN AFRICA

TOP-NOTCH SATE LLITE S OLUTIONS

Bypassing unreliable transmission lines African satellite communication solutions provider Telstream Telecoms has launched a number of new satellite services this year that have drastically reduced satellite bandwidth costs, allowing remote mine sites to stay connected while bypassing unreliable local infrastructure.

52 I NS IDE MI NI NG 0 7 | 2 0 1 3

Stay connected. Wherever.

Keeping your projects connected: Satellite internet Satellite phones Portable BGAN terminals Personal satellite tracking

Telstream Telecoms â&#x20AC;˘ +27 (0)11 783 4221 www.telstream.co.za â&#x20AC;˘ info@telstream.co.za

INFRASTRUCTURE IN AFRICA

U

SERS HAVE REALISED savings in excess of 50% on their current satellite connectivity costs by switching to these new services, says Telstream Telecoms’ owner, Darryl Kletz.

The company provides VSAT satellite internet and point-topoint satellite connectivity, allowing companies and organisations to provide their remote offices and projects with reliable communications, independent of local infrastructure.

“We also stock and support Iridium, Inmarsat and Thuraya satellite phones and accessories, as well as portable BGAN (Broadband Global Area Network) satellite terminals. We strive to ensure that, using the latest satellite technologies, your communications requirements are met.”

Telstream Telecoms is introducing a range of new devices to the market that will bring down portable satellite data costs further, allowing for the compression and acceleration of data when using portable BGAN terminals and satellite phones for data transfer. Built-in firewalls prevents unnecessary data being sent and received over links, allowing for the efficient use of these satellite technologies. Users are now able to more effectively use these devices in the field.

Providing Flexible Mining Solutions Takes Great Skill.

Tracking trends “From an occupational health and safety point of view, many mining companies are adopting internal policies requiring employees in the field and travelling throughout Africa to carry satellite phones with built-in tracking capability, such as the Iridium 9575 ‘extreme’ satellite phone,” Kletz points out. This technology provides employees with voice, text and basic data connectivity while in remote locations and allows companies to monitor the whereabouts of their personnel via a web interface and e-mail check-in facility. Employees also have easy access to help in cases of emergency through the built in SOS button, which will notify specified individuals and rescue centres.

While more and more areas are being provided with cellphone coverage throughout Africa, there are still gaps in this coverage and areas where it is unreliable. Traditional tracking and communication devices rely on GSM coverage.

“We encourage users of satellite services to approach their current providers to review their current contracts or alternatively look into comparative services to take advantage of these lower costs, improved speeds and more reliable connectivity,” concludes Kletz.

When it comes to mining, it’s not just about digging deep into the earth – it’s about digging deep into your skills and determination to make mining activities safer, more economical and more rewarding for your business.

Call us, or visit www.twp.co.za TWP South Africa T 0861 TWP TWP (SA) / +27 11 218 3000 E twpinfo@twp.co.za

INS I D E M I N I N G 0 7 | 2 0 1 3 53

INFRASTRUCTURE IN AFRICA

B E S T WO OD E STATE

Upper-class development for Kathu miners Esorfranki is on schedule to complete all civils works for the Bestwood Estate project in Kathu, Northern Cape

The estate will primarily accommodate employees of the local mining companies.

Green says the project site is characterised by the occurrence of a huge percentage of solid calcrete rock and he expects that more than 100 000 m³ of rock will be blasted during the civil works and crushed on-site for use as backfill. Esorfranki’s scope includes installation of 18 km water, 14 km of sewer and 14 km of gas reticulation.

Some 90% of the equipment being used on the development belongs to Esorfranki and was deployed to site by road from its Johannesburg headquarters.

There are currently about 300 Esorfranki personnel on-site, with an equal number of subcontractors. Esorfranki is doing its own concrete work and, wherever possible, subcontracts have been placed with local firms, while local labour has been employed for general site work. An in-house SETA-accredited trainer is involved in imparting machine operator skills to some of the local labourers, who are granted Certificates of Competence in these skills on successful completion of the training. To date, Esorfranki has recorded zero LTIs and Green attributes this to the fact that safety is the highest priority onsite. Two permanent safety officers ensure that safety remains top of mind among all completed, we’re releasing the stands in site personnel, through activities such as inbatches to the builders. So far we’ve handed ductions and daily Toolbox Talks. over 87 stands from the first phase and 20 Local cement suppliers are donating a from the second phase and will be handing percentage of their sale of concrete to the over about 45 stands per month from now project to the Kgalagadi Legacy Foundation, until completion.” Located on a 200 ha site initiated by the developers of Bestwood Esadjacent to the N14 at Kathu, Bestwood tate in Kathu, with the intention of leaving Estate is being developed by Share Africa behind a legacy for the benefit of the residition to a range of afdents of the estate and a Housing and, in addition the greater comfordable housing, munity of the Kgait will ultimately lagadi region.

INTERESTING INFRASTRUCTURE include schools, The cement will retail, hospitalbe used for the South Africa has the 10th largest road network ity, medical and building of instiin the world, roughly 606 000 km of roads, 155 000 km of this total is surfaced. sporting facilitutional facilities 3 128 km of the 155 000 km are tolled – ties, as well as such as schools Sanral CEO, Nazir Ally. places of worship. and clinics.

As main contractor on the Bestwood Estate project in Kathu, Northern Cape, Esorfranki Civils is on schedule to complete all civils works on this new mixed-use human settlement development by the third quarter of 2013.

T

HIS IS ONE of the biggest housing projects we’ve worked on in recent years,” says Mark Green, Esorfranki Civils director. “In addition to its magnitude, the project differs from the norm in that civils and building work are taking place simultaneously to meet the tight deadlines associated with this extremely fast-track development.

The project will help alleviate the accommodation shortage in the area, which continues to be problematic as the mining sector continues to boom in the region.

“Civils infrastructure work on 1 700 stands commenced in February 2012, followed by the start of building activities in April 2012. As the civil works are

54 I NS IDE MI NI NG 0 7 | 2 0 1 3

INFRASTRUCTURE IN AFRICA

F L EXI BLE WATE R INFRA S TR UC TUR E

Reaping the benefits Extractive industries are major users of fresh water, but are also producers of wastewater. Because these industries are critical to the continuous development and growth of Africa, sustainable and responsible growth as well as cost-effective and flexible water management, treatment, nt, reclamation and reuse infrastructure infra are required.

INTERESTING INFRASTRUCTURE

N

UWATER HAS built its business from the ground up specifically to cater to the water treatment, desalination and reuse requirements of the mining sector, specifically in sub-Saharan Africa. Its rapidly deployable large-scale modular and mobile plants are proving ideal for addressing the challenging, and often changing, water treatment requirements of customers operating in these sectors.

The company’s success to date has been based on its ability to offer a comprehensive solutions and services offering incorporating proprietary and integrated third-party technologies, operations and maintenance services, and financing solutions.

According to John Holmes, NuWater CEO: “Technology remains a key element of NuWater’s plants. Our patented 16-inch reverse osmosis (RO) technology has allowed us to build compact mine wastewater desalination plants that are modular, rapidly deployable and, where necessary, redeployable, as they

56 I NS IDE MI NI NG 0 7 | 2 0 1 3

require minimal ultrafiltration (UF) The modern electric utility industry in the fixed infrastrucand RO to reclaim United States can be traced to the invention of the practical light bulb in 1879 by Thomas ture.

However, high-quality water Alva Edison. Edison realised that his light bulb technology is just from mine wastewould mean nothing unless he developed an one part of the water for reuse at entire electric power system that generated and distributed electricity. By 1882 he had installed equation and ulEskom’s neighthe world’s first central generating plant on timately our cusbouring Lethabo Pearl Street in New York City’s financial district. tomers look for power station. This Reciprocating steam engines provided the providers that can completely modumotive power to generators, which produced direct-current electricity. deliver a complete lar and redeployservice offering able plant continto ensure they have water security and ues to address the mine’s treatment requireoperate within the environmental regulaments for water pumped from the pits and tions. This often includes NuWater financthe reuse of the reclaimed water for cooling ing as part of or the entire required water purposes at the power station reduces the treatment infrastructure. load on local water resources.

“Responsiveness and delivery capability “Our plant at New Vaal is a great examunder demanding conditions is always critiple of how NuWater’s pioneering solutions cal to success when working with demanding complement the creative water reclamation mining customers, and no more so than in and reuse plans of Anglo and Eskom. By Africa,” Holmes reinforces. providing a complete water treatment and Recent project successes appear to supreclamation service, it has allowed Anglo port NuWater’s claims of its capabilities to to achieve its goals without outlaying capdeliver comprehensive solutions to complex ital and the associated risks of ownership,” and challenging requirements. Its 20 Mℓ/d Holmes continues. plant at Anglo American Thermal Coal’s Similarly, NuWater’s plants at Gold Fields’ New Vaal colliery in South Africa combines Tarkwa mine in Ghana have provided flexible water treatment and desalination infrastructure in a very short space of time. Holmes explains: “The Gold Fields Ghana project consists of three separate plants, each combining UF and RO, with a combined treatment capacity of 14.5 Mℓ/d. These plants have been provided as a combination of equipment rental and sale, offering the infrastructure flexibility required by the mine.”

NuWater is also increasingly involved in larger water treatment and desalination projects where its high-performance RO technology and its design and execution capabilities complement the scale and broader engineering capabilities of its strategic partners, such as Murray & Roberts.

SUPERIOR TECHNOLOGY. SUPERIOR MINING SOLUTIONS. NUWATER MODULAR TREATMENT PLANT Seawater

Surface Water

Groundwater

NuWater provides a range of products, services and financing solutions to reclaim or treat almost any quantity and quality of water.

Waste Water

Clean Water

Innovative 16" reverse osmosis technology makes NuWater plants more compact and efficient, with lower operating and maintenance costs.

Being modular and mobile, our plants are also rapidly deployable and highly scalable, providing ultimate flexibility in a rapidly changing world.

People

Mining

Industry

Oil & Gas

Challenge us to clean your water.

Wastewater Reclamation

FROM TOP: NuWater’s ‘Modular & Mobile’ plant design for wastewater treatment and desalination.

Aerial view of 20 MLD mine wastewater reclamation plant at Anglo American’s New Vaal Coliery.

One of two NuWater rapidly deployable modular plants at Gold Fields, Ghana.

info@nuwaterglobal.com

+27 21 531 0641

www.nuwaterglobal.com

INSID E M IN IN G 0 7 | 2013 57

INFRASTRUCTURE IN AFRICA

DOO R S T E P DOCKING

Spot-on solution

Flotation solutions provider Dockpro, established in 2010, may have initially targeted the leisure market, but has quickly realised the attraction its product range offers the mining industry, MD Rob Clarke tells Inside Mining.

D

OCKPRO WAS established in 2010 as a specialist supplier of dry docking and jetty solutions in the Seychelles. The Southern Africa branch was established soon after. “As our experience with the product grew, so did our vision of other potential markets. Today, our modular floating system has expanded into many different industries due to its enormous versatility, durability and convenience, and we predict major success in the mining sector,” says Clarke.

Dockpro supplies turnkey flotation solutions such as pump platforms, pen stock access walkways and pontoons. All systems can be equipped with railings, A-frames and any other custom requirements using the company’s local engineering and fabrication.

The strategy going forward is to supply turnkey solutions for any water-based mining and industrial applications. Dockpro’s product range is constructed using high-quality material that is durable and environment-friendly. “We have a development team working with fabricators to construct commonly used systems, but we also offer customised design and fabrication of systems and accessories according to each customer’s needs. Our substantial stock holding allows for timeous distribution

58 I NS IDE MI NI NG 0 7 | 2 0 1 3

INTERESTING manufacand installation, which is INFRASTRUCTURE tured using hugely appealing to the Nikola Tesla and George Westinghouse built the a highly mining sector.” first hydro-electric power plant in Niagara Falls. a d v a nced Dockpro’s floating sysAdam’s Power Station (Power House No 3), the mould detem is modular, making only remains of the old Niagara Falls Power Plant, may become a science museum. sign deit easy to transport, asveloped in semble and reconfigure Canada. This produces an HDPE cube with or expand. The cubes are constructed with varying wall thickness providing rigidity, virgin HDPE (high-density polyethylene) stability and strength to cope with high and are remarkably resistant to impact, extraffic volumes. However, the design also treme climates, the adverse effects of water allows great flexibility to cope with rough and the sun, and a wide range of chemicals. water conditions and fluctuating water levThe dock stability, non-slip surface and high els. The non-slip surface is an important load capacity of 68 kg/cube, (or 272 kg/m²) safety feature. Lastly, the system is chemare characteristics that further provide an ical and impact resistant. ideal product for mining customers.

“We believe that the trend is for compaTwo of Dockpro’s recent clients include nies to move away from heavy-duty custom Glencore Xstrata and BHP Billiton. “For manufactured metal flotation systems toXstrata, we supplied a dual water pump ward lightweight versatile systems such as system to supply fresh water to the mine. that offered by Dockpro. Our products fulDockpro constructed a 5 x 3 m dual floatfil the trend toward environment-friendly ing platform with 2 x 1 m² apertures for the solutions by being durable, not leaking pumps. This is accessed by an 8 m walkway harmful chemicals into the water, being with custom railings around the entire sysmaintenance free – therefore not requiring tem. The BHP Billiton project required us potentially harmful paint or varnishes – to provide access to the pen stock on a slurand being made of fully recyclable HDPE. ry dam. We constructed a 60 x 1.5 m walkDockpro fulfils the need for a product that way, incorporating a 5 x 5 m pontoon with can be reused, recycled and reconfigured, a 1 x 1 m² aperture, and custom railings.” and requires no maintenance, while still Dockpro technology having high load capacity and durability,” Clarke explains that Dockpro cubes are Clarke concludes.

INFRASTRUCTURE IN AFRICA

P OTABLE WATE R STORAG E

On track for UMK SBS Water Systems is proud to be working in association with Aecom on the manufacture, supply and installation of an SBS Tank to the UMK manganese mine near Hotazel in the Northern Cape.

60 I NS IDE MI NI NG 0 7 | 2 0 1 3

INFRASTRUCTURE IN AFRICA

T

HE SBS TANK will be used for potable water storage on the UMK mine site and has a gross capacity of 1 126 kℓ. This size tank takes about four working days to manufacture and will be installed on the site by the end of July 2013.

SBS Water Systems is currently in the process of obtaining its SABS ISO 9001:2008 accreditation, so all processes and procedures for this and all projects adhere to these standards.

UMK was established in 2005 and is a joint venture between majority blackowned BBBEE company Majestic Silver Trading 40 and Renova Manganese Investments, a fully owned subsidiary of the Russia-based Renova Group of companies.

UMK is currently the fourth largest producer of manganese in the world.

Small-scale mining commenced in 2008, concurrent with the development of the mine’s permanent infrastructure. Production was ramped up in 2010 to a level of approximately 2.04 Mtpa run-of-mine, following the successful completion of the

first phase of the mine development, the railway loop and the load-out silo.

Towards the end of 2011, the permanent crushing and screening plant was commissioned and the remaining production infrastructure was commissioned during 2012. During 2013, the infrastructure project should be officially completed when the mine offices and the remaining non-production infrastructure will be done. To date, the infrastructure project has been delivered within budget.

RIGHT Manufacturing department working on parts for the SBS Tank OPPOSITE UMK crushing and screening plant

INSID E M IN IN G 0 7 | 2013 61

Total Resin In Pulp Solutions Unlock Potential, Create Value Advanced ion exchange technology for recovering, upgrading, separating and purifying metals and minerals.

Along with conventional fixed bed and NIMCIX fluidised bed technology, Tenova Bateman Technologies offers solutions based on the proprietary MetRIX™ Resin in Pulp technology, which offers both continuous adsorption and elution.

Tenova Bateman Technologies offers differentiated, project-specific process technology and modular plant solutions for the global mining and minerals industry.

58 Emerald Parkway Road, Greenstone Hill, Johannesburg, South Africa +27 11 899 9111 enquiries.TMM@za.tenovagroup.com www.tenovagroup.com

Tenova Mining & Minerals

MATERIALS HANDLING

AR DBEL

Taking the African A new joint venture company established between DRA and ELB Engineering – ARDBEL – aims to redefine massive materials handling projects in Africa and was officially launched on 1 July, writes Laura Cornish.

E

LB ENGINEERING is already a materials handling specialist and its CEO, Stephen Meijers, is intent on taking its project capability ‘up a notch’. Thanks to the formation of ARDBEL, it will do just that.

DRA’s CEO, Paul Thomson, and Meijers first announced the formation of the ARDBEL joint venture company at the 2013 African Mining Indaba, describing it as a collaboration between the two organisations to combine the best of breed skills in terms of large-scale projects and materials handling.

Africa is ripe with opportunity for largescale materials handling projects that require engineering experience, expertise and, most importantly, critical mass. “While both companies are significant players within their respective fields, together they are able

62 I NS IDE MI NI NG 0 7 | 2 0 1 3

to offer the African mining market capacity for the larger and more complex projects, in both the EPC and EPCM space,” says ARDBEL’s MD, Ken Bromfield.

The company’s primary focus is to cater to high-volume commodities that need to be moved in bulk – iron ore, phosphates, coal and base metals – from pit head to export point (ports).

“In essence, this includes conveyors, pipelines, rail lines, stackers, reclaimers, loading, etc.”

As a joint venture business, ARDBEL already offers its

clients a legacy of successful mining and materials handling projects and a widespread African footprint. “This includes 23 African countries in recent years alone. With a resource base of nearly 2 000 engineers, project managers, etc., we are spoilt for choice in terms of selecting and matching the best suited staff to the job – our project teams will be formidable,” Bromfield continues.

MATERIALS HANDLING

market by storm In combination, both company skill sets complement each other perfectly. ELB’s strength and core business is materials handling, while DRA has the ability to handle significant sized projects with an “unparalleled depth of skills, wide track experience and recognition in the industry, which has established the company as an engineering leader”.

“The joint venture, in which both parties have an equal shareholding, enables ELB to extend its current capabilities and offerings into large-scale materials handling projects by leveraging DRA’s credentials together with its own,” Meijers reiterates.

Thomson adds: “The collaboration enables DRA to be able to extend its offering along the mining value chain, thus furthering its goal to be able to engineer and operate ‘pit-to-port’ engineering

solutions that offer an attractive benefit to new mine developers in Africa.”

project within the balance of this year and we are confident of achieving this.”

“Despite our target project size, we intend Down the line to be nimble and move quickly and being While both ELB Engineering and DRA will based in South Africa remains the ideal locacontribute equally to ensuring ARDBEL detion to do this.” Operating in the same time velops and prospers, the intention is to eszone as the project delivers an unparalleled tablish a unique identity and self-sustaining competitive edge. business as quickly as possible, operating ARDBEL’s focus at this stage is subindependently from its parent companies.

Saharan Africa where a lot of new iron ore It is already evalprojects are rapiduating various localy developing, but INTERESTING tions to establish its INFRASTRUCTURE lack infrastructure head office, which beyond their own will be near its pardoorsteps. Mozament companies. bique finds itself in Although still in a similar situation, its infancy, Bromthanks to the infield points out that crease in the numthe company has alber of coal mines.

The 2.46 km Millau Viaduct, which opened ready identified nuWith its huge inin 2004, is a cable-stayed road bridge that spans the valley of the river Tarn near Millau in merous opportunifrastructural develsouthern France. It is the 12th highest bridge ties and is ready to opment programme in the world, with a 270 m drop from the ‘move off the startand massive minbridge road to the valley below. ing blocks’. “We are eral resources, the already gaining acceptance and acknowllarge-scale materials handling requireedgement from the industry of who we are ments of Africa are substantial and growand what we have to offer,” he notes. “Our ing exponentially. Considering ARDBEL’s primary target is to secure one significant starting track record, both ELB and DRA are extremely positive regarding the potential growth that the collaboration offers ALL PICTURES ARDBEL will focus on in terms of further extending their ‘home large-scale materials handling projects in Africa market’ into Africa.

INSID E M IN IN G 0 7 | 2013 63

Everyday we move mountains for our clients.

We d o th is w i t h t h e l a t es t a n d be s t e qu ipme nt t h a t i s p u r p o s e d e s i g n e d f o r t h e i r s p e c i f i c n e e d s.

O p erating globally we re - define what it means to move th e e a r t h f o r o u r c l i en t s.

w w w. A RDBEL . com

MATERIALS HANDLING

CONQ U ESTX P

The toughest belt yet Goodyear Engineered Products, manufactured and sourced exclusively by Veyance Technologies, has launched its new conveyor belt ConquestXP, designed to withstand the toughest belting environments.

W

ITH 100 YEARS of innovative rubber compounding research, Goodyear Engineered Products was able to push the limits when designing the ConquestXP. The belt was developed using computer modelling and finite element analysis (FEA) software and is fortified with the power of Fortress Technology, which makes it extremely tough against punctures and impact.

“Also unique to ConquestXP is Shield, a fire-retardant runner compound with a low

smoke density and reduced toxic gas emissions. In case of a fire, this will result in improved visibility and lower toxic fume levels, making it ideal for underground mining applications,” explains Craig Rouhana, sales and marketing director of Veyance Technologies South Africa.

ConquestXP is designed for primary crushers, secondary crushers, mainlines, pit belts, and other

high-abuse applications. The innovative patented fabric provides improved bearing and impact resistance to sustain high-abuse applications. The dual layer twill fabric delivers high transverse tear strength, which minimises tears causing material punctures.

Other features include a superior rip resistance, which helps dislodge and expel foreign objects.

INSID E M IN IN G 0 7 | 2013 65

When I say I’ll deliver...

I deliver!

Ben Pretorius

Designed by Atomic Design Studio. Produced by Coralynne & Associates Tel: (011) 422-1949

Safety Officer

Together, the Johnson team delivers a SMART lift Safety | Maintenance | Availability | Reliability | Total Cost Effectiveness Tel: +27 (011) 455 9222 or 0860 CRANES | Fax: +27 (011) 455 9230

MATERIALS HANDLING

R AP IDLY RISING

Bakubung headgear South Africa’s platinum sector may be in the doldrums. But one local project – Wesizwe’s R7.9 billion Bakubung Platinum mine – continues to celebrate milestone achievements as it pushes forward with its first production target, writes Laura Cornish.

66 I NS IDE MI NI NG 0 7 | 2 0 1 3

MATERIALS HANDLING

emerges T

HE LATEST achievement, according to WorleyParsonsTWP project manager Robert Hull, was the successful erection of the main headgear. WorleyParsonsTWP is the appointed EPCM contractor responsible for all surface project work, terraces, offices, electrical facilities, winder houses,

shafts, headgears, ventilation fans, refrigeration plant and compressors, as well as all ancillary work including workshops, storage facilities, security facilities and access roads. “The 83-m high steel headgear (comprising just under 1 900 t of steel) was erected in just 18 days, impressive considering it was scheduled to take 25 days. The

lift was also brought forward by two weeks, allowing the shaft sinkers earlier access to complete change over to main sink,” Hull explains.

WorleyParsonsTWP’s steel headgear choice was strategic. “Our primary objective is to get to the reef in the shortest possible time frame. As a steel structure,

ABOVE The headgear comprises six centre portions LEFT The headgear was erected in 18 days

all the major components were fabricated and preassembled when they arrived onsite. They were then pieced together using a crane, which was the secret to the fast erection time frame, ensuring the main sinking activity was delayed for the shortest possible time.”

The headgear comprises twelve major sections; six centre portions, two supporting back legs, three complete sheave decks and an overhead crane structure. The largest lift, the first sheave deck, was over 200 t in a single lift. To achieve this a Sarens 1 000 t crane – the second largest available – was used to erect all sections of the headgear.

“The crane itself, which we reserved in November last year, is massive and is seldom in use. This meant it was essential that the headgear components were on-site and ready for lifting during the allotted time frame. The crane took over 60 truckloads to deliver to site and two weeks to erect,” Hull explains. 

INSID E M IN IN G 0 7 | 2013 67

MATERIALS HANDLING

The headgear was erected with a Sarens 1 000 t crane

Steel structure manufacturer Louwill Engineering detailed, built and installed the headgear and was also responsible for ensuring the crane was on-site. A team of over 50 member was on-site to preassemble, oversee and ensure a successful erection process. “We are extremely pleased that the project didn’t just meet the schedule but was delivered so well ahead of time.”

Designing a headgear is no easy task and takes numerous factors into account, including hoisting requirements (ore tonnage), depth of mining, cage arrangements, safety measures, fleeting angles and crane requirements.

“The Bakubung headgear will be used to service two 20 t skips, a 15-person service winder cage and a 150-person/14 t payload man and material cage. Our three winders are ground mounted and include a Koepe winder (for rock hoisting), a double drum winder (for men and material hoisting) and a single drum service winder. We prefer ground-mounted winders because they are easier to access and therefore easier to maintain,” Hull reveals.

Current project outline Hull says Bakubung’ s mine development is progressing well.

“To date it remains within budget and on baseline schedule.

We are overcoming a few ventilation shaft sinking teething issues and are comfortable with both shafts’ development.”

The ventilation shaft (7.5 m diameter) is currently just over 180 m deep and the main shaft (8.5 m diameter) is 120 m deep. Pre-sink on the main shaft is complete and roping up was completed in June allowing main sink activities to commence directly thereafter.

68 INSID E M IN IN G 0 7 | 2 0 1 3

MATERIALS HANDLING

The main shaft will reach a depth of 1 000 m and the ventilation shaft will reach 930 m. First station breakINTERESTING INFRASTRUCTURE away (just below 700 m) The Hoover Dam is a concrete arch-gravity is scheduled to start in dam in the Black Canyon of the Colorado January 2014.

River, on the border between the US states First production will of Arizona and Nevada. It was constructed be in 2018, followed by between 1931 and 1936 during the Great Depression. a four-and-a-half year ramp-up period. average stope width of 1.35 m) “WorleyParsonsTWP is also currently will be mined using convenunder way with a mining optimisation protional stoping methods and the gramme, looking at ways to increase mining UG2 reef (50 000 tpm, average efficiency, due for completion by year end. stope width of 1.5 m) will use Recently we were also awarded the order to semi-mechanised hybrid methcomplete a concentrator plant optimisation ods. Underground crushing is study to take the plant up to FEED level by planned to take place at the main June 2014 ready for the later concentrator shaft ore passes, from where the plant construction.” reefs will be separately conveyed Bakubung Platinum mine (formerly to stockpiles on surface before known as the Frischgewaagd-Ledig mine) the concentrator plant. has been designed to mine and process 230 000 tpm run-of-mine (ROM), delivering 350 000 ozpa of PGMs at full production for Lifting the supporting back legs into place 35 years. The Merensky reef (180 000 tpm,

INSID E M IN IN G 0 7 | 2013 69

Bidvest Laundry Group

Deeper than you’d expect For over 14 years Montana Laundries, a division of Bidvest Laundry Group, has entrenched itself in industrial laundry with unprecedented success by providing on-site, eco-friendly laundry solutions that’s coupled with efficient maintenance. Montana Laundries offers long-term convenience, cost-effective services and raw dependability that’s at the core of your mine.

Montana Laundries

First Garment Rental

Andrew Coates Divisional Manager T +27 11 975 1077 F +27 86 539 6758 C +27 82 879 8899 E acoates@firstgarment.co.za W www.bidvestlaundrygroup.co.za

Pysical Address 82 Rigger Road Spartan South Africa 1619

Contact us to enquire about our SME/BEE initiatives.

Postal Address P.O. Box 9556 Edenglen South Africa 1613

PROJECT DELIVERY

F L S M I DTH' S FIRST A FRIC AN S UPE R C E NTE R

Open for business The first FLSmidth Supercenter on the African continent – and the seventh of its kind worldwide – officially opened its doors on 6 June 2013 in Delmas, Mpumalanga.

E

SSENTIALLY AN extensive aftermarket hub, the new facility houses a concentrated stockholding and is poised to become the South African construction base service and repair facility for all FLSmidth activities.

“In other parts of the world, FLSmidth all-in-one Supercenters are established to realise our vision of getting closer to our customers,” says Stephan Kruger, general manager FLSmidth Supercenter. “These Supercenters are strategically located near customer operations to provide localised services that ensure timely delivery and support.

Through these state-of-the-art

facilities, our customer working relationships are expanded and services are tailored to meet their needs.

“The Delmas Supercenter is geared not only to offer warehousing, rebuild and repair capabilities, but also specifically to support plant efficiency and safety. The facility works alongside customers to boost their competitive advantage and fortify their safety record, since repairs and rebuilds will take place off-site in the controlled environment of the Supercenter.

“FLSmidth leads the way in minerals processing, material handling and cement technologies, and the Supercenter concept has been introduced to strengthen our commitment to a successful industrial sector. The

FLSmidth Supercenter facts FLSmidth Supercenters feature: • consultancy services to rapidly and effectively address customer issues • proximity to customers for timely delivery and support • strategic stock, so customers don’t have to wait for shipments • rebuild and repair capabilities to increase plant uptime • safety training for customers and employees • test work in conjunction with full-scale facilities • training rooms and tailored modules to assist customers, employees and others to learn to use equipment optimally • emphasis on environmental best practice and sustainability • community and educational outreach.

70 I NS IDE MI NI NG 0 7 | 2 0 1 3

PROJECT DELIVERY

Supercenter is more than just an innovative building design, it’s a partnership with our customers and with the local community.”

Kruger adds that establishment of this dynamic new facility effectively enhances FLSmidth’s local presence and underpins the company’s commitment to fostering customer intimacy by supporting customers through the life cycle of FLSmidth equipment in the field.

The Delmas Supercenter comprises a 750 m2 office and training centre complex, workshop, stores and tool store facilities of over 2 900 m2, and a mobile plant workshop and service facility of 635 m2. A canteen and change rooms are provided for employees, while the property – owned by FLSmidth – also provides a storage yard for all FLSmidth Roymec equipment not being used on construction sites.

The training centre will be utilised to instruct customers on the safe and efficient use of the company’s products, to train site staff in the specialist construction skills needed in the field and to maintain skills levels across the rest of the staff complement.

“At the new Supercenter, as in all of our facilities, every effort will be made to ensure environment - friendly practices and sustainability,” Kruger says.

“For example, contaminants and waste products will be removed from equipment in a contained washdown

INTERESTING INFRASTRUCTURE

The hydroelectrical project at Inga Falls in the DRC will generate 40 000 MW of electricity, with the first phase costing US$9 billion (R90.17 billion).

area for proper removal and disposal. To conserve water and reduce energy consumption, rainwater will be collected for irrigation and power is generated by solar energy whenever feasible. Natural light is used to best advantage. All of this is, in addition to the work we do, to offer products that are efficient, save energy and offer environmentally friendly solutions to customers.”

Other FLSmidth Supercenters are located in Tucson, Arizona in the US; Perth, Australia; Arequipa, Peru; Antofagasta and Santiago, Chile; and Khanbogd, Mongolia.

INDEX

INDEX TO ADVERTISERS AAD Group

50

NuWater

57

ARDBEL

64

Read, Swatman and Voigt

19

Atlas Copco CTS

41

Sandvik Mining

32

SBS Water Systems

60

Babcock International Group

2

Bauma Africa

36

SEW Eurodrive

51

Bell Equipment SA

13

SMEC

47

Bidvest Group

69

Southern Mapping

49

BLC Plant Company

15

Telstream Telecoms

52

Booyco Electronics

29

Tenova Bateman

61

Consulmet

44

Tenova Delkor

IFC

DockPro

59

ThyssenKrupp

OFC

Esorfranki

55

TWP

53

OBC

UMP

34

Exxaro Resources First Solar South Africa

11

UWP Consulting

72

Husqvarna

35

Vermeer

68

Johnson Crane Hire

65

Vital Engineering

21

MineRP

39

Voith Turbo

20

Multotec

71

Winder Controls

72 I NS IDE MI NI NG 0 7 | 2 0 1 3

IBC

CUTTING-EDGE TECHNOLOGY Mining • energy • infrastructure Mechanical • Planning and construction of turnkey hoisting plants: • Shaft hoisting and Installations • Skip and cage hoisting systems • Inclined hoisting system • Conventional and Integral Koepe Winders • Complete refurbishment of all types of mine winders • Head and DeÀection Sheaves • Mobile Winders • Skips and Cages • Rope attachments • Rope load measuring devices • Loading and Unloading stations • Rope Clamping and Lifting Devices • Winder Brake Upgrades • Multi Rope Handling Equipment • Single Rope Handling Equipment • Rope Tensioning Equipment • Fluid transportation systems • Pressure Exchange Systems for Energy recovery • Transportation of cooling Àuids for mine cooling systems • After sales service • Spares and Equipment

AUTOMATION DIVISION 56 Stanley Street Extension 3 Germiston South Africa Telephone: +27 11 776 5000 Fax No: +27 11 776 5090 E-mail: winder@winder.co.za Website: www.winder.co.za

Automation • PLC Integrated Systems using "Mitsubishi" • Speed Distance Control • Speed Distance Protection • Automatic Rock Winders • Automatic Multi Level Man Winders • Monitoring & Safety Circuits • HMI Display • Drive Systems • AC Option - Preferred Supplier • DC Option - Preferred Supplier • Controls • Single and Double Drum Winders (Vertical and Incline) • Koepe Winders • Stage Hoists • Winches • Reelers Sub Systems • Main Drive Hoisting Systems • Auxiliary Motor Controls & LTDB • Escort Brake Systems • Electronic Lilly EHMU II • DC Breakers • Bell Signalling Systems • Driver's Desks • AC/DC Motors • SEC Electric Machinery • DC Motors • AC Slip ring Motors • AC Synchronous Motors • TMEIC • AC & DC Motors • After sales service • Spares and Equipment

HOISTING DIVISION Unit 15, Lakeview Business Park Yaldwyn Road Jet Park 1459 Telephone:+27 11 383 9300 Fax No:+27 11 383 9305 E-mail: Info@winder.co.za Website: www.siemag-tecberg.com

POWERING POSSIBILITY