Inside Mining November December 2014

www.miningne.ws

IN THE

AFRIC AN UPDATES ON THE

GROUND AND UNDERGROUND

SPOTLIGHT Anthony Turton What Einstein taught us about AMD

DC ARC FURNACE Nonferrous metals recovery

MATERIALS HANDLING Innovation from within

OPEN-PIT MINES Dealing with stormwater

H2O Mine closure and rehabilitation

ISSN 1999-8872 • R50.00 (incl. VAT) • Vol. 7 • No. 11 • November/December 2014

CONTENTS AFRIC AN UPDATES ON THE

ENDORSED BY

November/December N ovvem o ve em m 2014

GROUND AND UNDERGROUND

EDITORS COMMENT ON THE COVER O

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P4

N NuWater and scalable minewater ttreatment Clean up your water or stop mining. This is the stark o rreality facing an increasing number of mines around the world as the o ttrue impact of their operations on tthe quality of local water resources becomes evident. b

Keeping his legacy alive

COVER STORY

4

Mine wastewater treatment

AFRICA ROUND-UP

6

Mining news from around the continent

IN THE SPOTLIGHT

8 10

What Einstein taught us about AMD Alarming biodiversity report

FERROUS & NONFERROUS METALS

12 16 18

Recovering nonferrous metals using DC arc technology New smelting technology Coega to lead South Africa’s national metals beneficiation strategy

MINE CLOSURE & REHABILITATION

20 22 23 24 26 29 30

Considerations in mine closure Mine closures: a long-term liability Acid rain more important than carbon emissions Are mining rehabilitation funds still needed?

Mining impact on groundwater Clamping down on illegal mining Retaining land value after closure

MAPPING

31 20

Orthoimagery

LEGAL

32

Zambia’s exploration and mining policies

ENERGY

34

The energy imperative

TECHNOLOGY

35 37 39 41 42 43

Measuring productivity Compressor achieves 35% energy saving Focus on processing efficiency Weir Minerals expands into new technology 60 Years: A piece of history Extreme environment EPCM

MINE SERVICES

44 24

Na-Sera: Uniquely different

MATERIALS HANDLING

46 47 48

Major empowerment deal Innovation from within Lower emissions and fuel consumption

PIPES, PUMPS & VALVES

50 51 54 55

Getting out of deep water Piping caustic liquids Creative alternative Value-driven water management solutions

THIS & THAT

41

56 56

In remembrance…

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IN SID E M IN IN G 1 1 /1 2 | 2014

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EDITOR'S COMMENT

Publisher Elizabeth Shorten Editor Tony Stone Online editor Sylvester Haskins Head of design Hayley Mendelow Senior designer Frédérick Danton Designer Kirsty Galloway Chief sub-editor Tristan Snijders Sub-editor Beatrix Knopjes Contributors Joost De Vree, Jon Duncan, Mike Jessop, Rodney Jones, Val Kofoed, Duncan Mcmeekin, Johnathan Meintjies, Betsie Strydom And Anthony Turton Production manager Antois-Leigh Botma Production coordinator Jacqueline Modise Marketing manager Hestelle Robinson Digital manager Esther Louw 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 Tazz Porter Tel: +27 (0)11 465 5452 Cell: +27 (0)82 318 3908 tazz@connect.co.za ___________________________________

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Keeping his legacy alive

A

YEAR AGO, on the 5 December 2013, Nelson Mandela died. It is important that we remember him in this issue of Inside Mining as it spans the first anniversary of his death. For me it is a particularly poignant time, as I got to know him personally. Privileged to talk to a cross section of people who knew him well, people who spent time with him on Robben Island, I wrote a tribute honouring Madiba on behalf of the Black Methodist Consultation, a black-consciousness movement headquartered in the Eastern Cape. Meeting Madiba in person on that occasion, and later in celebrating his 90th birthday, gave me an intimate understanding of this great leader, this distinguished Son of Africa.

One thing I do know, and know well, is if South Africa is to remain the Rainbow Nation, the land of the free, we must never let go of his legacy, his values and the principles he held so dear, and for which he was prepared to die. Now, while we slowly slip into the quagmire in which we find ourselves today, we need to revisit and apply every aspect of the South African Constitution, to its letter and intent, and not as is being conveniently interpreted by African nationalists today.

Madiba’s 1964 Rivonia Trial speech, it seems, has turned out to be quite prophetic. When I asked him what the most important thing was that he learned, while incarcerated on Robben Island, he said, “Forgiveness! It’s the greatest power on Earth.”

Since October 2014, I have visited a number of mines and have been inspired by their commitment to society and their care for the environment. At the same time, there are mines that do not carry the same sense of social responsibility.

In this issue, we talk about mine closure and rehabilitation. I must commend the Wits School of Animal, Plant and Environmental Sciences for the amazing work they are doing in Orkney and elsewhere, in particular Dr Isabel Weiersbye and Dr Jenny Botha.

To discover that eucalyptus trees, used for controlling the hydrology (water flow) around mine dumps, actually absorb grains of gold is simply fascinating. In fact, knowing that different species of plants can be used for different mine rehabilitation purposes, such as the reduction of radioactivity on uranium mine tailings dumps, ushers in a whole new world of knowledge and the ability to work with nature to clean up the mess humans make.

In keeping our environment in mind, the recovery of nonferrous metals – major pollutants – is a critically important function. With the advent of DC arc furnace technology, developed and refined by Rodney Jones and his team at Mintek, mines are reprocessing their slag in which nonferrous metals occur in commercially viable quantities. Of interest, and across the ocean, Australia has discovered a new source of nonferrous metals. In this mining case study, DC arc furnace technology is once again being used to recover the nonferrous metals that occur in abundance in this resource – municipal solid waste dumps.

Last but not least, we look at the various legal, financial and insurance aspects of mine closure and rehabilitation. One entrepreneurial mind is already at work in turning an old quarry into a gold mine with a difference.

We must never let go of his legacy, his values and the principles he held so dear

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COVER STORY

NUWATER

Scalable mine water Clean up your water or stop mining. This is the stark reality facing an increasing number of mines around the world as the true impact of their operations on the quality of local water resources becomes evident.

I

NCIDENTS SUCH AS the recent Mount Polley disaster in Canada’s British Colombia, where a tailings pond partially breached, releasing 10 million m3 of mine wastewater and 4.5 million m3 of slurry into a pristine lake, only serves to highlight the potential impact of untreated mine wastewater on the local environment, and the wildlife and communities living there. While largescale incidents such as this are relatively rare, they do also draw attention to smaller water management transgressions at other mines that may ordinarily not have been identified by regulators, or even by the mines themselves. Once attention is drawn, however, the backlash is often swift and severe, as has been evidenced at a number of mines around the world where Gold Fields selected NuWater to provide its rapidly deployable modular plants, for its operations in Tarkwa, Ghana

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INS I DE MI NI NG 1 1 / 1 2 | 2 0 1 4

regulators or communities have either threatened, or achieved, mine shutdowns.

It is not only existing mining operations that are under pressure to demonstrate adequate levels of water custodianship.

New mine licences are almost always contingent on guarantees being provided that mine wastewater will be adequately treated, both during the life of the mine and beyond. This is forcing mining companies to factor in the true cost of water management from the start of new projects.

Water management, as part of the mine design and management process, is complex and there is almost inevitably an element of water remediation required. NuWater identified this challenge to the mining sector some time ago and has established itself as an international leader in mine wastewater remediation, a position further reinforced by a multi-year extension of its contract with Anglo American Thermal Coal’s New Vaal colliery where

NuWater owns and operates the mine wastewater treatment and desalination plant, and has been delivering reliable and cost-effective services for over three years.

According to John Holmes, NuWater CEO, “A key part of NuWater’s value proposition is the reclamation and reuse of mine wastewater to reduce a mine’s water footprint, ensure its environmental compliance and help it make a valuable contribution to social and environmental sustainability. We don’t just look to sell equipment and services but rather aim to partner with mining companies to help them manage their water resources. We are focused on providing the most efficient and effective water and wastewater treatment and management solutions, leaving our customers free to focus on their core mining activities.”

Innovative solution NuWater’s solutions cover the full range of mine wastewater remediation requirements, from pH adjustment and control, through heavy metals and suspended solids removal, to the removal of dissolved solids (desalination). NuWater offers innovative, high-recovery and zero-liquid-discharge solutions that facilitate the complete separation of contaminants from pure water, leaving little or no liquid

treatment

In 2010, NuWater was awarded the project at Anglo New Vaal colliery to build, own and operate a treatment and desalination plant to treat up to 20 000 m3/day of mine wastewater. NuWater proposed its modular and mobile plant design as an alternative to convention and inflexible fixed infrastructure. This enabled NuWater to have the first treatment capacity commissioned within weeks of contract signing.

Treatment capacity was then ramped up over the next three months through the addition of further ‘modules’. The modularity of the plant has allowed capacity to be added and reconfigured over the course

is such that Eskom’s water treatment requirements are significantly reduced. This is a fantastic example of how a successfully executed project and close collaboration can make a real contribution to environmental sustainability.” waste to deal with. In some cases, valuable Following on from NuWater’s early success components can also be recovered from at Anglo American, Gold Fields, in 2012, sethese solid waste streams to help offset the lected NuWater to provide two of its rapidwater treatment costs. ly deployable modular plants, one treating 3 600 m3/day and the other 7 200 m3/day, Water challenges for its operations in Tarkwa, Ghana. Once The challenge of treating mine wastewaagain the modularity and rapidly deployable ter is much more than a technical one. nature of NuWater’s plants were key factors Holmes explains: “If mines aren’t able to in the selection process. Gold Fields also access affordable mine wastewater treatbenefited from NuWater’s ability to delivment solutions it can quite easily make er on the very short project timeframe by the mine financially unviable. This has an leveraging its operations in South Africa, immediate knock-on impact on jobs and Singapore and the UK. Furlocal, or even national, thermore, NuWater’s ability economies. At the same to offer commercial flexibiltime it is also clear that ity through a combination the longer-term costs of of equipment rental, equipnot adequately treating ment sale, and operations mine wastewater are far and maintenance services allarger than ensuring corlowed Gold Fields to achieve a rect treatment from the cost-effective solution to their start. A case in point is the pressing mine wastewater enormous challenge and treatment requirement. cost faced by Gauteng to According to Holmes: address acid mine drain...the modularity and rapidly “Our work with Gold Fields age from historical gold deployable nature of NuWater’s demonstrates the value mining activity. plants were key factors in the of our rapidly deployable “NuWater’s strategy is mine wastewater treatment able to offer mining comselection process solutions. We have had to panies an efficient and affordable cost of ownership solution, of the project with minimal impact on work closely with the Gold Fields’ team which factors in the capital costs, ener- day-to-day treated water production. This to navigate both technical and logistical gy efficiency and other operational costs flexibility has proved invaluable as the challenges, including operating in a very over the life of the project.” feed water characteristics, product water remote location. Our interests are fully NuWater has taken this ‘total cost of quality requirement and the volume of aligned with those of the customer as we ownership’ a step further by offering cus- water requiring treatment have changed both own some of the equipment and protomers commercial solutions that remove over time. The reliability and flexibili- vide operational services and support.”

Holmes concludes: “The challenge of almost all the technical and operational ty of the plant was also instrumental in risk for the customer. This involves Nu- NuWater securing a further multi-year mine wastewater treatment continues Water retaining ownership of the plant extension to this contract, as it provided to grow. There is no substitute for expewhile also operating and maintaining it. the customer with complete comfort that rience and a proven track record in the This can be achieved in a number of ways NuWater could adapt its operations to demanding mining sector, both of which depending on the predictability of the future changes in the mine’s wastewater NuWater has earned. More importantly, we believe our integrity and passion for treatment requirement. NuWater typical- treatment requirements. ly recovers its capital and operating costs Holmes notes, “The treated water from innovation will continue to differentiate for such projects based either on the vol- NuWater’s plant is reused by the neigh- us from our competitors.” ume of water treated, or on a fixed plant bouring Eskom Lethabo power station availability fee along with a variable pro- as cooling water. This project is therefore duction-based fee. According to Holmes, not only ensuring that mine wastewater “It is not a case of one-size-fits-all, but is safely managed and treated, but is also rather about providing as much flexibility helping to reduce Eskom’s dependency on as possible to match the operational and water from the Vaal River. The quality of t +27 (0)21 531 0641 financing preferences of our customers.” the water produced by NuWater’s plant www.nuwaterglobal.com 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.

IN SID E M IN IN G 1 1 /1 2 | 2014

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AFRICA ROUND-UP

MINING NEWS

from around the conƟnent

NAMBIA

Okorusu closing Okorusu Fluorspar Mine, one of the largest in the world, is expected to shut its doors next month, a process that will see about 407 workers jobless.

Situated north of Otjiwarongo in the Otjozondjupa region, the mine is not only known for its success but also for controversies after several people were forced out of surrounding farms to accommodate the mine in 2005, according to The Namibian.

Solvay Chemicals, the mine’s parent company, this week announced that it will close the mine after 26 years of operation because it is not economical as a result of depleted high-grade ore resources.

The mine had 407 workers – 321 full-time staff and 86 contractors. The company said all employees will be given appropriate notice of termination of employment by the end of November under severance conditions.

Phenomenal growth anticipated The Namibian mining industry grew by 6% during Q2 2014 compared to a 6.6% contraction during the same period in 2013 with growth expected to grow ‘phenomenally’ as new mines come into full production, said Namibia’s Chamber of Mines CEO, Veston Malango, in October.

“The mining industry continues to be the backbone of the national economy and will be for many years to come,” Malango told media in Namibia.

The Chamber of Mines CEO specifically pointed out Husab mine, which constitutes an investment of N$22 billion,

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which, once in full production, will become the world’s second largest uranium mine, ranking Namibia second in global uranium production.

Otjozondu sale agreement Otjozondu Mining, a subsidiary of Shaw River Manganese, has signed a purchase contract with Noble Resources International for the sale of 30 000 tonnes of manganese ore from the Otjozondu manganese project in Namibia.

The company is currently in the final stages of completing its infill and grade-control programme and anticipates commencing with mining of bulk samples of approximately 100 000 tonnes in early November 2014.

turn them into a profitable venture, according to reports.

ICVL signed the pact on 28 July to buy Rio Tinto’s 65% stake in Benga and 100% each in Zambeze and Tete East coal assets in the African nation.

Shanghai Power signs Ncondezi MoU Ncondezi Energy has entered into a memorandum of understanding with Shanghai Electric Power (SEP) whereby the Chinese firm will become the controlling shareholder of the 300 MW power plant project in Mozambique.

Ncondezi announced in October that the mutual intention for further cooperation between SEP and Ncondezi is documented in the MoU, which also sets out a work plan and timetable for the project. The two parties intend to execute a legally binding heads of terms joint venture agreement during Q4 2014.

REP. OF CONGO MOZAMBIQUE

$500 million investment State-owned Indian mining firm International Coal Ventures (ICVL) will invest $500 million in the Mozambique coal mines over the next two to three years.

The investment will be directed towards creating logistical and infrastructure support at the recently acquired Benga coal mines in the country.

ICVL purchased the Benga mine from Rio Tinto Coal Mozambique in a $50 million deal completed in September.

The deal included other coal projects in the Tete province of Mozambique.

ICVL is now also looking to appoint a full-time official with rich experience in coal mining to head the operation of the Mozambique mines to Zambian Finance Minister Alexander Chikwanda

INS I DE MI NI NG 1 1 / 1 2 | 2 0 1 4

African Potash growth Sub-Saharan Africa-focused African Potash on 22 October saw a jump in its shares of over 5% upon news that it intersected multiple potash seams at the second exploration drill hole at its Lac Dinga potash project, in the Republic of Congo.

African Potash announced in late October that it completed its second and final hole of its first drill campaign at Lac Dinga after successfully intersecting potash mineralisation.

The two-hole drill pro-

gramme tested two high-priority targets at the flagship project, which is located in a world-class potash bearing region in the Republic of Congo and it hasn’t disappointed.

The latest hole intersected a 112 m thick salt sequence made up of multiple potash seams totalling about 48 m, 43% of the total interval.

The company’s chief executive, Edward Marlow, said the successful intersection of multiple potash seams at Lac Dinga was an ‘exceptional endorsement’ for African Potash’s exploration concept as it supports his confidence that the project has the potential to host a large-scale commercial potash mine.

ZAMBIA Scrapping VAT Zambia could simplify its monetary policy amid a dispute with mining companies over VAT, which the country is looking to scrap for the sector next year.

Mining firms would face a higher mineral royalty rate in Zambia instead of corporate tax, regarded as hard to administer, if the fiscal restructuring and VAT requirements of the country are approved, according to reports.

Zambia, the continent’s second largest copper producer is withholding $600 million in VAT refunds owed to mining firms and will only repay the cash when companies produce import certificates from destination countries, the Minister of Mines said in June. The African nation, which last year lost its position as Africa’s top copper miner to Congo for the first time since 1998, began enforcing the rule last year in order to curb tax avoidance.

In August, Finance Minister Alexander Chikwanda announced the government had decided to relax the rule because it proved very hard to implement, mainly because it

AFRICA ROUND-UP

involved documentation from importers outside the country’s jurisdiction.

Miners accused of blackmail The Zambian government accused several mining companies of blackmail as they protest withheld VAT payments.

Several mining companies threatened to halt operations and lay off their workers over $600 million withheld in refundable VAT. Yaluma said there were many avenues by which affected companies could negotiate with the government for the VAT refund.

“My ministry will not hesitate to take punitive action against companies trying to blackmail the government via workers’ retrenchments,” Zambia’s Minister of Mines, Energy and Water Development, Christopher Yaluma, told media.

VAT rules: under VAT rule number 18, companies, including those that export and import goods and services, are allowed to demand a tax refund for exported or imported goods and services.

Citing exaggerations on the part of some companies for refunds, the government, now insists that companies must produce a certificate of shipment and tax invoices from the country of origin/destination.

Companies that have proof are refunded by the Zambia Revenue Authority (ZRA) while those unable to produce the certificates, including mining companies, are not.

GUINEA

ARM takes on Ebola South African mining executive Patrice Motsepe has donated R10.94 million towards the fight against Ebola in West Africa. The founder of African Rainbow Min- Mining magnate erals (ARM) Patrice Motsepe

donated the sum, on behalf of the Motsepe Foundation and ARM, to the Ebola Fund in the Republic of Guinea.

Motsepe made the commitment to Guinea in September and the appropriate regulatory approvals were obtained on 24 October 2014.

The donation will assist Guinea with clinical management, social mobilisation, medical coordination and other key mechanisms of controlling the disease.

Motsepe has called on the African and international business community and the medical fraternity to continue contributing and assisting to fight the disease, which has claimed thousands of lives in the latest outbreak.

“According to the World Health Organisation, Ebola is an epidemic in certain countries in West Africa. However, the impact of the disease has potentially far-reaching consequences for West Africa, Africa and the world. It is a global issue which requires the global community to work together and bring an end to the disease” said Motsepe.

Humanitarian catastrophe On 28 October, the Disasters Emergency Committee (DEC) warned that West Africa was 60 days away from a ‘humanitarian catastrophe’.

The DEC launched an unprecedented appeal to secure millions of pounds to fund the fight against Ebola.

The appeal called for donations to pay for the running of

treatment centres, the provision of protective clothing to medical workers, and the protection of children orphaned by a disease that has already killed nearly 5 000 and threatens to infect more than a million people by the new year.

TANZANIA

Iron and steel boom Tanzania is expected to export the first consignment of iron ore and steel in four years, according to Tanzania’s National Development Corporation (NDC).

The NDC announced in October that the sector is set to produce 1.1 million tonnes annually – with the country on track to be one of the top four iron producers in Africa, once commercial production of the commodity takes off, stated the NDC. Acting NDC MD Mlingi Mkucha told East African Business Week that an iron and steel metallurgical complex is in the works, which will result in the creation of hundreds of jobs in the country.

The two licences for Liganga Iron Ore and Mchuchuma Coal Mine were presented by the Minister for Energy and Minerals, Prof Sospeter Muhongo.

“The construction of the iron ore mining and iron smelting plants at Liganga will start early next year and production is scheduled to start in 2018,” Mkucha said.

Sichuan Hongda JV Tanzania’s construction of new coal and iron ore mine projects located 900 km south-

Mwana mine, Zimbabwe

west of Dar es Salaam in 2015 is anticipated to cost $3 billion, according to reports The projects will be developed in a joint venture deal signed in 2011 with China-based Sichuan Hongda.

The Tanzanian government plans to raise its stake in the JV from 20% to 49%, according to an Investec report.

ZIMBABWE

Gold spike Mwana Africa’s Zimbabwean operations’ Freda Rebecca and Trojan Nickel mines reported 23% and 5% production growth, respectively, in Q3 2014.

This was due to an increase in running hours and throughput rate, said Mwana in its quarterly statement.

Gold output at Freda Rebecca stood at 16 555 oz in the second quarter for financial year 2015 compared to 13 503 oz in the previous quarter as a result of improvements in feed grade, recovery and milled tones.

Gold recovery for the quarter was 3.2% higher at 80% compared to 76.8% in the previous period, said the company.

The average gold price received during the period was 2% lower at $1 272/oz.

At Trojan Nickel, Mwana Africa said concentrate production was 5% higher at 1 989 tonnes, owing to a 3% increase in the tonnes mined, to 160 741 tonnes from 155 610 tonnes, from the previous quarter as the refurbishment of equipment programmes was completed.

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IN THE SPOTLIGHT

What Einstein

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The problem of AMD (acid mine drainage) has been with us for fo some time. Yet, it continues to plague us. Why? In looking for the answers, we look to theoretical physicist and lo p philosopher of science, Albert Einstein. BY ANTHONY TURTON

LBERT EINSTEIN taught us many fundamental principles of science. One of his protégés was a man called Joseph Rotblat who later became my own mentor after bringing me into the Pugwash movement. I have thus always had a personal interest in Einstein, because in many ways I feel only one step removed from his thinking. It is with this in mind that I have worked in a high-impact technical team to solve the problem of acid mine drainage.

The South African economy is based on mining. Had gold not been discovered in 1886 the Anglo Boer War would not have been fought and this country would not be as we know it today. The epicentre of this was the Witwatersrand goldfields.

Over a 120-year period, gold mining created the foundation for a national economy, built the city of Johannesburg into the financial centre of Africa, and drove one of the largest human migrations in modern history. It also gave us four unintended consequences now manifesting as constraints to the future economic development and job creation capability in Gauteng.

Unintended consequences The first unintended consequence is AMD. The second is the presence of a large volume of surface tailings, collectively containing a staggering 430 000 tonnes of uranium discarded as waste. The third is the presence of numerous openings into the void, resulting in geotechnical instability for surface development as well as giving access for illegal mining syndicates to residual gold. The fourth is the existence of a large swathe of land, about 100 km long and 2 km wide, known collectively as mine residue areas (MRA), most of which is contaminated by hazardous tailings, but is also home to a growing population of informal settlers. Collectively these four problems now confront the captains of industry and decision-makers in government with a major dilemma. Let us call these four unintended consequences of gold mining legacy issues, for sake of convenience.

The question now arises – how can we deal with the dilemma arising from these legacy issues? A dilemma is by definition insoluble, because it represents a choice between alternatives each mutually unattractive. The first step in solving these legacy issues is to convert them into a series of problems.

A problem, by definition, is soluble, so in the context of legacy issues problems are desirable whereas dilemmas are not.

The best way to covert a dilemma into a series of problems is to apply Einstein’s thinking. One of the key elements of his teachings is the

simple but eloquent statement that the level of ingenuity needed to solve a problem exceeds the level of ingenuity that created it in the first place. This means that we collectively need to mobilise more ingenuity to solve the AMD issue than we had when we were the largest gold producer in the world. This principle has been applied by a junior mining company on the Western Basin when they developed the tailings water treatment (TWT) technology.

This solution is based on the observation that the historical business case for mining was based on a model that maximised profits at the level of shaft or pit by externalising environmental liabilities. The unit of management is thus the mine and the industry stood on one leg – the legal licence to mine. By shifting up one level, and by aligning the outcome of the mining process with the broader interests of society – the social licence to mine – a wider range of benefits can be defined and distributed across a wider range of beneficiaries. Central to this logic is the optimisation of all processes in order to achieve a desirable outcome for society as well as shareholders.

In the context of TWT, the simple logic is that barren tailings are deposited at a pH of around 10.5, because this is the optimal level for the extraction of gold via the cyanidation process. By exposing AMD to barren tailings, a few important things happen: • the pH is neutralised at very low cost • the precipitated mixed-metal hydroxides form on the tailings particle, enhancing the settling rate, but also sequestering the uranium in the form of a chemically stable mineral • there is no need for a separate high-density sludge stream, which has major cost savings for any long-term solution to AMD

Part of the TWT plant as it looked during the trialling of the technology for regulatory approval

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INSI INS I DE MI NI NG 1 01 6 / |1 22 0| 1240 1 4

IN THE SPOTLIGHT

taught us about AMD • a strong business case is made for the reclamation of all existing tailings dams, using the revenue from the recovered gold to fund the rehabilitation of mine dump footprints while consolidating the many smaller dumps into a few megadumps engineered to 21st century safety standards • the life of marginal mines can be extended by as much as 30 years, creating jobs in an industry shedding jobs, while buying time for the rehabilitation of mine-impacted ecosystems and landscapes • the tailings need not be deposited on the surface; they can technically be placed underground in such a way as to close out the void permanently, while also restoring the geotechnical stability needed to develop the MRA land for higher social use post mining • because this process requires the movement of massive amounts of surface tailings, the final landscape can be sculpted d to any form required for a post-miningg urban development scenario.

By thinking out of the box, the TWT development team has thus created a shift in paradigm. Wherever there are tailings with small amounts of residual gold, AMD in need of neutralisation and MRAs in need of rehabilitation for higher social use post mining, the TWT technology can be applied.

Trial results have shown that the quality of treated water from the TWT process is identical to that from the HDS process; therefore any additional treatment technology such as reverse osmosis systems can use this feedstock. Experimental work k currently underway has shown that the addition of a biological phase can also remove sulphate. This needs to be scaled d up from the laboratory to a pilot plant, which is likely to happen when the TWT technology enters the next stage of the licensing process.

created a national economy, but the externalities from that process are now a constraint to future economic development and job creation. Innovative solutions are needed to create a soft landing.

Theoretically this is possible, but it requires three critical success factors to become a reality. First, we need an uncontested vision of how a post-mining landscape might look. This is being provided by the Wits University School of Architecture and Urban Planning.

Second, we need an institutional arrangement capable of bringing all parties together to operationalise that vision. This is being driven by the DWS in the Wonderfontein

Spruit Forum. Third, we need bankable projects to emerge from this process.

Experimentation to this effect is currently happening for the rehabilitation of highly impacted wetlands in the upper Wonderfontein Spruit.

Seen in this context, there is cause for optimism in declaring a shift from blame-seeking to solution-seeking behaviour in the mine closure debate.

THE AUTHOR Anthony Turton Trained scientist specialising in water management

In conclusion The historic business model that underpinned mining over the last 120 years FIGURE 1 (Top) Schematic overview of the tailings water treatment (TWT) process FIGURE 1 Closure mining model showing how the overall recovery of surface tailings aligns the outcome of mining with the broader interests of society

IN SID E M IN IN G 1 1 /1 2 | 2014

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IN THE SPOTLIGHT

Alarming biodiversity report

A new report finds a one third non-adherence to government’s Mining and Biodiversity Guidelines.

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study into the standards of environmental assessment practitioners (EAP) in the mining sector has revealed an alarmingly high non-adherence to the government’s new Mining and Biodiversity Guideline (MBG).

These findings are contained in a report commissioned by the WWF South Africa and funded by the WWF Nedbank Green Trust entitled ‘Mining and Biodiversity: Evaluating EAP standards in the sector’.

The report calls for fast-tracking the appointment of EAPASA (Environmental Assessment Practitioners Association of South Africa) as the registration authority for EAPs to ensure compliance and higher standards in the industry.

The study scrutinised 62 mining applications submitted for mining in the Enkangala Grasslands and surrounding areas over a period of a year.

Alarmingly, at least a third of the 1.6 million hectare WWF-SA Enkangala Grasslands project domain – across KwaZulu-Natal, Mpumalanga and the Free State – is currently subject to some form of prospecting or mining application, according to the report. The wider grasslands domain is home

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to over 4 000 plant species, 15 of South Africa’s 34 endemic mammals and 10 of our 14 globally threatened bird species.

It is also vital for crop food production, foraging for livestock and game farming, and tourism and recreation among other things. More importantly, the Enkangala Grasslands are a critical water source area, giving rise to the Vaal, Thukela and Pongola rivers. With water recognised among the scarcest resources in South Africa, grasslands – and their water catchment systems – are crucial for our country’s water security as well as supporting sustainable economic and social development.

The study’s objective was to analyse the mining applications for their adherence

to the six core principles of the government-endorsed MBG as released in May 2013. While the guideline holds no legal standing, it provides pointers to existing biodiversity information and tools, and how they can be used to integrate biodiversity considerations at every stage of the mining life cycle.

“The approximately 30% margin of non-adherence by EAPs to the MBG principles is too large to ignore and is cause for concern when considering the context of coal mining and its associated impacts,” the report says.

This confirmed what was already being experienced in practice, namely “that certain EAPs and/or mining houses are apparently disregarding critically important environmental information in the completion of their coal mining or prospecting applications.”

The three main areas of contention were MBG principles TOP Coal mining in the

Enkangala Grasslands LEFT WWF International

director general Dr Marco Lambertini (centre) met with WWF-SA CEO Dr Morné du Plessis (left) and chairman Valli Moosa

IN THE SPOTLIGHT

compared the performance of smaller, less two, four and six that relate to the idenSouth Africa is serious about meetestablished or experienced versus largtification of biodiversity priority areas, ing its climate change and sustainable er or more established/experienced EAP best practice for environmental impact development targets. consultancies and found that there were assessments and ensuring the effective If this substandard EAP performance in substantial gaps in performance, with implementation of environmental manthe mining sector continues, we are also agement programmes that include unlikely to halt or decrease the plans for rehabilitation of landscapes current loss of biodiversity in the after mining. of mining activities in our “...biodiversity that supports context “Environmental assessment pracvital grasslands,” says Du Plessis the provision of ‘ecosystem in conclusion. titioners play a critical role. They are meant to filter applications with services’ vital to people and acceptable impacts from those that Acknowledgements Diagram illustrateconomic activities.” would have unacceptable environing the hydrological functioning of a typmental impacts, and to then present ical pan after mining and rehabilitation smaller consultancies being “less than sattheir findings to the relevant authorities have been completed, Professor Terence McCarthy, isfactory” in their adherence to the MBG in an objective manner – thus promoting Professor Bruce Cairncross, Professor Jan-Marten principles. sustainable development in South Africa,” Huizenga and Dr Allan Batchelor, Universities of This indicates a need for monitoring and says Morné du Plessis, CEO of WWF-SA. Witwatersrand and Johannesburg, and Wetland more training on the applicable legislaThe MBG states that biodiversity priorConsulting Services. tion, and the MBG, before they can even ity areas “are important for conserving be considered for registration under a probiodiversity that supports the provision fessional body like EAPASA. of ‘ecosystem services’ vital to people BELOW Map of the Vaal catchment area “Full compliance with the six baand economic activities. Their loss would BOTTOM Acid mine water drainage has sic MBG principles is necessary if be difficult or in some cases impossible become a major issue for South Africa to compensate or offset; there are no cost-effective substitutes for many of the services they deliver,” as evidenced by defunct, ownerless mines such as the Makateershop mine located in the study area that has effectively destroyed the freshwater provisioning capabilities of the sensitive environment.

Examples of ecosystem services include nature’s provision of fresh water; indigenous vegetation such as grasses providing soil stabilisation and erosion control; as well as carbon storage in trees and plants.

“We cannot underestimate the vital importance of these majestically powerful, yet silent, ecosystem services performed by nature, every day,” says Angus Burns, WWF-SA Grasslands programme manager.

“Yet on a weekly basis we are approached by concerned landowners who are custodians of sensitive water-producing land under direct threat from inappropriate mining or prospecting applications.”

“The failure to apply this biodiversity priority area principle results in major clashes between the biodiversity and mining sector. It also carries major risk for the mining houses and can become a costly exercise for all parties involved,” the report says.

Similarly, the failure to adhere to MBG principles four (use best practice EIA) and six (ensure effective implementation) increased the risk of biodiversity loss in the coal-mining sector and flew in the face of responsible mining. Part of the study also IN SID E M IN IN G 1 1 /1 2 | 2014 11

FERROUS & NONFERROUS METALS

Recovering nonferrous metals using

DC arc

technology

H

ISTORICALLY SPEAKING, DC arc furnaces were patented by Sir William Siemens in 1878 but only became widely commercialised in the 1990s. DC arc furnaces were first used industrially for the reductive smelting of chromite fines

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With the Earth’s diminishing resources, recovery of valuable nonferrous metals such as cobalt, nickel, and copper from slag dumps, using DC arc furnace technology makes a lot of business sense. BY RODNEY JONES

to produce ferrochromium 30 years ago.

Since then, they have been used for a variety of applications, including the smelting of ilmenite to produce titania slag and pig iron, the recovery of cobalt from non-ferrous smelter slags, and the smelting of nickel laterite ores to produce ferronickel.

The power of these furnaces has increased from 12 MW to 72 MW for ferrochromium, and to 80 MW for ferronickel. The largest of these furnaces requires two electrodes to carry sufficient current to generate this much power. A review is presented of some of the various DC arc furnaces in

FERROUS & NONFERROUS METALS

use, along with a discussion of the likely ways in which furnace power might be increased further in the future.

Features of DC arc furnaces A DC arc furnace typically comprises a refractory-lined cylindrical steel shell, with a central graphite (cathode) electrode vertically positioned through an opening in the centre of the roof. The anode connection in the hearth of the furnace is in direct contact with the layer of molten metal that is covered by a layer of molten slag. The energy is supplied by means of an open plasma arc that is generated between the bottom tip of the cathode and the upper surface of the molten slag. At least a central portion of the slag surface is open (uncovered by feed material).

Because the furnace is electrically powered, very high temperatures (>1 500°C) can be attained. The open bath allows fine feed materials to be fed into the furnace, without risk of blocking the gas emanating from the chemical reactions. By contrast, in a blast furnace, or in a submerged arc furnace, coarse feed materials are required in order to provide a porous bed that allows the reaction gases to percolate away and escape from the reaction zone.

Finer ores and a requirement for very high temperatures lead one to the choice of an open-arc furnace (either AC or DC). It should be noted that fine ores allow the use of a fluidised-bed reactor for OPPOSITE Tokyo Steel’s 175 MW twincathode DC-arc furnace FIGURE 1 (Below) Schematic diagram of a DC arc furnace

pre-heating or pre-reduction, and this can provide significant energy savings when used in conjunction with a DC arc furnace.

In the case of open-arc furnaces, DC furnaces have a number of advantages over AC furnaces.

One particular advantage in a circular furnace is that there is no arc repulsion in the case of the single DC arc, compared to the AC case where the arcs repel one another, flaring towards the walls, leading to hotspots on the areas of the side-walls in closest proximity to the electrodes. DC furnaces also experience lower electrode consumption. In large DC furnaces, a higher current can be carried per electrode (or smaller electrodes can be used for the same current), because of the AC ‘skin effect’ where current is concentrated in the outer periphery of the electrodes.

Some past and current applications of DC arc furnaces South Africa is very fortunate in having large reserves of chromite. Unfortunately a lot of the ‘Transvaal chromites’ are highly friable, resulting in large stockpiles of fine ore materials. This posed a particular challenge to Mintek to provide a solution to this problem. Peter Jochens of Mintek identified ‘plasma furnaces’ as a possible solution to the ‘chromite fines’ problem.

Mintek and Middelburg Steel and Alloys (now part of Samancor Chrome) conducted smelting trials on Tetronics’ pilot transferred-arc plasma furnaces in the UK in 1979/80. These trials showed successful metallurgy, but this type of furnace was seen as difficult to scale up to the very large furnaces that were required for the

ferro-alloys industry. Around about the same time, also in the 1970s, ASEA in Sweden developed high-power thyristor rectifiers. Sven-Einar Stenkvist investigated the conversion of AC open-arc furnaces to DC, principally for steelmaking. He implemented the idea of using a graphite cathode electrode arcing onto a slag/metal bath as the anode, and devised an electrically conductive hearth and a hollow graphite electrode for finely sized iron ore smelting, where the feed material is fed through the electrode and through the heart of the plasma arc.

Nic Barcza of Mintek recognised the synergy between the metallurgy that was proven during the Tetronics test work, and the scale-up potential of ASEA’s DC arc furnace. This is where the application of pre-baked graphite electrodes in a DC arc furnace came about. Mintek built a 1.2 MW DC arc furnace in 1983 to support this development. Since then, that concept has been applied in a number of areas. The first industrial application of a DC arc furnace for smelting came about when Middelburg Steel & Alloys converted an existing AC furnace at Palmiet Ferrochrome (now Mogale Alloys) in Krugersdorp to a 12 MW DC arc furnace of ASEA design in 1984.

Chromite smelting Mintek began investigating alternative smelting methods for ferro-alloy production in the mid to late 1970s. The growing ferro-alloy industry in South Africa faced the problem of how to deal with the significant quantity of fine material (< 6 mm) that was generated from the

IN SID E M IN IN G 1 1 /1 2 | 2014 13

PROJECTS &INNONFERROUS FERROUS AFRICA METALS

the fine material is dropped, and it almost friable local chromite ores. In 1976, studin slag composition unconstrained by immediately assimilates into the molten ies commenced on the possible use of plaselectrical properties, so that the chemical bath, melting and dissolving into the slag ma smelting (DC transferred-arc technolactivities of the important metals can be phase where the reactions take place. This ogy), motivated by its potential ability to changed to achieve higher chromium refurnace does not require coke because utilise fine feed materials directly, without covery. A typical increase in chromium rethere is no burden above the bath so it costly agglomeration. A further advantage covery could be from about 85% in an AC doesn’t require the porosity that would was that the metallurgical and electrical furnace to about 95% in a DC arc furnace otherwise be needed. This is a very signifiparameters of the smelting process are in– a very significant increase. In addition, cant advantage, in that it allows the use of dependent, unlike in a conventional subthe DC arc furnace has lower electrode inexpensive reductants, thereby avoiding merged arc furnace. consumption. The DC arc process althe high cost and relative scarcity of coke.

In 1979, Middelburg Steel & Alloys asked lows the use of unagglomerated chromite The power supplied to the furnace is Mintek to take part in tests on plasma fines and cheaper, non-coking coal. This largely independent of the slag composmelting at Tetronics in the United Kingfurnace technology is regarded as one of sition, because there is an open electric dom. After that, Mintek committed itself the lowest-cost options for the production arc that allows one to adjust the amount to the investigation of plasma technoloof ferrochromium. of power going into the furnace indegy, and to the demonstration to industry Based on the successful operation of the pendently of the electrical resistivity of of its benefits, particularly the ability to DC arc furnace for chromite smelting at the slag. This provides extra flexibility and smelt fine materials. Equipment for this Krugersdorp, Middelburg Ferrochrome an extra degree of freedom of a change purpose was installed in Mintek’s pilot (now part of Samancor Chrome) built a 44 bays, and was based initially on MW (62 MVA) DC arc furnace, a power supply of 100 kVA, and the largest of its type, in MiddelDC ARC TECHNOLOGY ELSEWHERE later on another of 3.2 MVA. The burg in 1997. This was followed, Very large DC arc furnaces are currently in first such ferrochromium was proin 2009, by an additional 60 MW use in the steel industry. For example, in duced in a bench-scale DC arc furfurnace in Middelburg, current2007, Tokyo Steel ordered the world’s largest nace in 1979. The installation of ly the largest DC arc furnace in electric arc furnace (EAF) from Danieli. This the large experimental furnaces in South Africa. The 44 MW furfurnace has a 420 t liquid steel capacity. It Mintek’s pyrometallurgy pilot bay, nace was subsequently upgraded is a twin-cathode DC arc furnace, with four bottom electrodes. The power supply includes Bay 1, demanded an extension of to 60 MW. 8 x 32 MVA transformers, making up a total the original building and, in June of 256 MVA. The operating power is 175 MW. 1982, a formal inauguration of Ilmenite smelting Danieli claims that it overcomes the limits of the larger 3.2 MVA furnace. The 1 Ilmenite is smelted to produce power input in the EAF, and reduces graphite t/h DC arc furnace pilot plant was titania slag (mostly for pigment electrode consumption, as compared with commissioned in 1984. production) and pig iron. IlmenAC and single-cathode DC furnaces, and As a result of successful initial ite from beach sands in South disturbances on the power supply network test work, Mintek and Middelburg Africa is of too low a grade to be are minimised due to the double-arc effect.

Steel & Alloys undertook a longerused directly for the production The largest DC furnace used in the steel term R&D programme to develof pigment or synthetic rutile. industry (175 MW) is substantially larger op the technology commercially.

Instead, it is smelted to produce than the largest of the DC smelting furnaces (currently 80 MW). Perhaps the steel industry Based on test work at 0.3 MW to a titania slag suitable for the prowill lead the way for future expansions in 0.5 MW in furnaces 1 m to 2 m duction of TiO2 pigments. The capacity elsewhere. in diameter, the initial industriprincipal reaction involved is al-scale 16 MVA (12 MW) transshown simplistically as: ferred-arc furnace was installed at FeO.TiO2 + C = TiO2 + Fe + CO the Krugersdorp (Palmiet FerroThe high electrical conductivchrome) plant of Middelburg Steel ity of titania slags and the re& Alloys at the end of 1983, then quired accurate control of the upgraded (around 1987) to 40 slag composition effectively rule MVA (~33 MW) in 1988. An adout the use of conventional subditional 10 MW furnace was later merged-arc technology for the built on the same site (for Mogale smelting of ilmenite. Richards Alloys).

Bay Minerals (RBM) uses process Chromite is smelted together technology originally developed with some form of carbon to proby Quebec Iron & Titanium (QIT duce ferrochromium, along with Fer et Titane) of Sorel, Canada, some slag and some CO gas. The employing rectangular six-inDC arc furnace operates with an line graphite-electrode furnacopen-arc, open-bath configuraes in open-bath mode with AC tion, so there is no heaped burden open-arc operation. through which the reaction gasAn alternative to this process, es would need to escape. There is based on single hollow-electrode simply a molten bath onto which DC-arc furnace technology, was

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FERROUS & NONFERROUS METALS

for expensive agglomeration techniques.

Because of the high moisture content of laterites, the ores should be dried and calcined before smelting. A further saving in energy consumption can be achieved by pre-reducing the ores.

Mintek has been working on the production of unrefined ferronickel from nickel-containing laterite in DC arc furnaces since 1993. In this process, lateritic material is fed, together with a carbonaceous reducing agent, to the central region of the molten bath of a cylindrical DC arc furnace. A wide compositional range of nickel laterites can be smelted in this way.

The flexible operation of a DC arc furnace (especially its lower dependence on electrical properties of the slag, because of open-arc operation, in addition to the ability to run at an optimum slag temperature, due to the open-bath mode of operation) allowed for the successful treatment

developed by Mintek and Anglo American Corporation for the Namakwa Sands project. The problem that needed to be solved was to find alternative equipment in which to produce a very conductive slag. Because the slag is so conductive, it is not feasible to obtain sufficient resistive heating in the molten slag, and it is, therefore, necessary to use an open arc.

(This is a very different reason for using a DC arc furnace from requiring it for smelting chromite fines.)

Phase one of the test work, in 1990, involved four 15 kg batch tests at 30 kW, and showed that the process was feasible, and that a freeze lining was required.

Phase two, in 1991, involved smelting two metric tonnes of ilmenite, with continuous feeding at 50 kg/h, at a power level of 100 kW. This produced an on-specification slag, and a metal that was high in Ti. Phase three, also in 1991, saw the smelting of 35 tonnes of ilmenite, fed continuously at 300 kg/h, at power levels of 500 kW (to 1 MW), with on-grade slag and metal produced. Phase four, in 1995, processed 200 tonnes of ilmenite at 1 t/h and 1.5 MW, and primarily involved the development of the furnace startup procedure, process control, and operator training.

Following the 0.5 MW pilot-plant test work in a 1.8 m diameter furnace, the first 25 MW DC arc furnace at Namakwa Sands was constructed in 1994, followed by a 35 MW DC furnace in 1998. The first furnace began production of ilmenite slag and pig iron in June 1995, and the second furnace was brought on line in February 1999.

Based on that success, without any further test work being required at Mintek, two further 36 MW DC furnaces for ilmenite smelting were built for Ticor SA, near Empangeni, and were commissioned in 2003. A further 30 MW furnace was built

by Bateman and commissioned for CYMG in China in 2009.

of ores with a SiO2/MgO ratio between 1.2 and 3.0, as well as ores containing up to 30% by mass of iron (which tends to cause slag foaming in a conventional immersed-electrode furnace).

A frozen lining can be maintained between the molten bath and the refractory lining, in order to minimise refractory wear (especially at high SiO2 contents).

The smelting of nickel laterite to produce ferronickel was piloted at Mintek from 1993 to 2006, using a wide variety of feed materials. The first commercial application of the DC FeNi process was a 12 MW DC arc furnace in Orsk in the Southern Urals, Russia, commissioned in September 2011.

Nickel laterite smelting

Kazchrome

Laterites and other oxidised nickel ores constitute a very important part of worldwide nickel reserves. In the conventional production of ferronickel from these ores, much fine material is produced which cannot readily be accommodated directly in existing three-electrode or six-inline AC furnaces. DC arc furnace technology allows ore particles less than 1 mm in size to be treated directly, thereby improving the overall recovery of nickel without the need

Kazchrome (a ferrochromium producer in Kazakhstan) contracted with Mintek in 2007 to undertake smelting test work.

Based on this, and on other design inputs provided by Mintek in 2009, SMS Siemag has built four 72 MW DC arc furnaces in Aktobe, Kazakhstan, and commissioning was scheduled to begin in 2013. Each of these furnaces features an automated online electrode changer for the 75 cm graphite electrodes, and a suspended roof.

Koniambo nickel The largest application of DC arc furnace smelting technology is the Koniambo Nickel project in New Caledonia – a greenfield joint venture partnership between Société Minière du Sud Pacifique (SMSP) and Glencore Xstrata. The process is based on milled ore, fluidised beds, and two twin-electrode 80 MW DC arc furnaces, with cyclone pre-heaters. Each 71 cm graphite electrode has a separate 40 MW power supply (transformer and rectifier).

The smelting test work for this project was carried out at Mintek in the late 1990s. The Koniambo ferronickel smelter, which will employ about 800 people, aims to produce 60 kt/a of Ni in FeNi from one of the world’s largest and highest-grade nickel laterite deposits. The smelter commissioning began in 2012, and the first metal from the furnace was produced in April 2013.

In conclusion

DC arc furnaces are very well suited to a number of reductive smelting processes

DC arc furnaces have some wonderful features that have been proven in industrial practice over the past 30 years. They are good at accommodating finely sized feed materials (because of the open bath) and do not require coke or char (no burden porosity required).

DC arc furnaces can treat feed materials with a wide range of compositions (because of the extra degree of freedom coming from power being supplied by an open arc); this allows a choice of chemistry for metallurgical benefit. These furnaces are geometrically simple and elegant, thereby reducing uneven wear on side-walls, and leading to lower costs.

However, there are some drawbacks.

Thermal efficiency is decreased by the hot off-gas leaving the furnace (unless some of this energy is recovered). The absence of a burden does not allow for the capture of volatile species. DC arc furnaces are not a panacea for all metallurgical problems, but are very well suited to a number of reductive smelting processes where they have been applied successfully in a number of industrial contexts, and many further applications are expected.

THE AUTHOR Rodney Jones Pyrometallurgy division, Mintek, and president elect of the South African Institute of Mining and Metallurgy

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FERROUS & NONFERROUS METALS

New (ish) smelting technology The commercialisation of a new smelting technology is not something that happens very often, yet, when it does, it doesn’t happen quickly. It takes about fifteen years from the initial pyrometallurgical research to full industrial implementation.

COMPILED BY TONY STONE*

O

VER THE PAST few decades, DC arc furnaces have been used for smelting processes where significant chemical reactions are involved. Mintek has been fortunate enough to be involved in the industrial-scale commercialisation of at least one application of this technology per decade. This started with the smelting of fine chromite ore to produce ferrochromium in the 1980s, and was followed by the smelting of ilmenite to produce titania slag and pig iron in the 1990s.

In both of these cases, the process chemistry was well known and the products were familiar (albeit with some minor variations), even though the type of furnace was novel at the time. A further example was the use of a DC arc furnace to recover metals (principally cobalt) from nonferrous smelting slags early in the 2000s. In this case, a new process TOP A DC arc furnace in action

16 INS I DE MI NI NG 1 1 / 1 2 | 2 0 1 4

was carried out in a ‘new’ piece of equipment to produce a somewhat unfamiliar intermediate product. This, therefore, required testing and demonstration at quite a large scale. The most recent (2013), and largest, commercial application of DC arc furnace smelting has been the Koniambo project in New Caledonia where nickel laterite ore is smelted to produce ferronickel.

There is currently another application of DC arc furnace technology that is poised on the brink of commercialisation – namely the ConRoast process, which can be used for both platinum group metal (PGM) and nickel smelting.

The ConRoast process was developed to address a number of the shortcomings of the traditional matte smelting process for the production of platinum group metals.

It controls sulfur emissions by removing sulfur from concentrates prior to smelting. It easily accommodates high levels of chromite by ensuring that the chromium

is dissolved in the slag. The concentrates undergo reduction in the furnace, and the PGMs are collected in an iron-rich alloy that has a similar liquidus (‘melting’) temperature to that of the slag.

The ConRoast process Mintek has been working since 1994 on the development of an alternative process for base metal and PGM smelting that offers greater flexibility and is more environmentally favourable. The ConRoast process is based on reductive smelting in a DC arc furnace in the effective absence of sulfur, where an iron-based alloy is used to collect the valuable metals. The original impetus for the process was environmental, but, once developed, it became apparent that the process had another significant advantage for the platinum industry in South Africa, as it was not affected at all by the chrome issues that have caused problems for the traditional ‘six-in-line’ smelters. These challenges are:

FERROUS & NONFERROUS METALS

However, the principal drawback of condistinct advantage. This is their story.

The sulfur problem: The emission of ventional technology is that it is largely Their unique access to the ConRoast proSO2 (sulfur dioxide) from furnaces and unsuited to the processing of chromecess enables the company to unlock the converters is hard to avoid when using rich UG2 reef, nickel-rich Platreef ores inherent PGE (platinum group element) a sulfur-based matte-smelting process. and chrome-rich LG and MG reefs, withvalues in the traditional chrome ores via However, the ConRoast process does out mixing concentrates from these rethe extraction of PGEs and chrome from not rely on the presence of sulfur, as it sources with those from the Merensky near- or at-surface platinum-containing smelts essentially sulfur-free material in reef. The UG2’s higher concentration of chrome reefs. These ores were traditionala DC arc furnace and collects the valuachromite affects the conventional smeltly only mined for its in-situ chrome with ble metals in an iron alloy. Sulfur can be ing process by gradually choking furnaces the PGEs either lost as part of the runremoved, prior to smelting, using a fluidwith insoluble chrome spinels with collatof-mine ore sale or trapped within the ised-bed roaster, which is a well-enclosed eral damage to furnace linings. tailings from the chrome beneficiation vessel that produces a steady continuous While the current platinum smelter process and deposited on surface. The stream of SO2 that can be used for the operators are largely locked into their ability of the ConRoast process to recovproduction of sulfuric acid (if the conconventional plants, emerging producers er the PGEs from this chrome-dominant centration and scale warrant this course have until now been constrained of action). Compared to the trato having their UG2 concentrates ditional matte-smelting process, The ConRoast technology smelted by these operators, who emissions of SO2 can be orders of have to blend these concentrates magnitude lower if the ConRoast has been taken through to their own UG2 and Merenprocess is used. The capital costs implementation, to Jubilee’s with sky concentrates. This has sigof acid production can also be distinct advantage nificant limitations on the new reduced markedly. producers’ capacity. Various othThe chromium problem: The er experimental smelting technologies ore structure affords Jubilee a unique traditional matte-smelting process imhave been tried over the years, but with opportunity to unlock the inherent PGE poses strict limits on the quantity of chrolimited success. values. Jubilee’s medium-term plans mite (prevalent in the UG2 reef) that can The ConRoast process developed, testenvisage constructing PGE concentrabe present in the smelter feed. This coned, proved and patented by Mintek, South tor plants capable of producing up to 15 straint restricts the recovery of the PGMs Africa’s state-owned minerals technology 000 oz of PGEs in concentrate annually in the production of ore concentrates. laboratory, represents a major advance. and targeting growth to reach an annual The ConRoast process eliminates the It opens up the possibility of mining the production of 50 000 oz of PGEs in conchromium constraint in smelting and so vast tonnages of UG2 reef that form part centrate within five years through access opens up huge opportunities in the types to near- or at-surface of materials that can be smelted, and platinum- containing provides an opportunity to significantly chromite reefs. The enhance the overall process recovery of company has applied to PGMs (through removing the restrictions the DMR for PGE minin concentrator operations). ing rights to its ElandsThe containment problem: As the South drift and Bokfontein African platinum producers have moved chrome-bearing farms increasingly to processing ore from the near Brits in the westUG2 reef to supplement the previous ern limb of the Bushproduction from the Merensky reef, there veld Igneous Complex have been numerous furnace failures and (BIC). The company also explosions in the industry. Even though has applied for the PGE water-cooled copper cooling systems and chrome prospecthave been introduced in recent years, the ing rights to 69 other highly superheated and corrosive molten farms in the area. matte in traditional smelters is inherConventional ‘six-inently difficult to contain. The ConRoast line’ platinum smeltprocess is able to use a simple and robust ing technology coupled design of furnace, because the melting with Pierce-Smith contemperatures of the slag and alloy are verters, though well unclose to each other. derstood, is at least 40 years old and is highly From research to implementation polluting, particularly Through an initial collaborative partfrom emissions of fuginership between Mintek and Braemore tive sulfur dioxide gas.

Resources, the latter of which was subsequently acquired by Jubilee Platinum, First slag tap from the ConRoast technology has been taken Mintek’s 3 MW furnace, through to implementation, to Jubilee’s 4 October 2008 IN SID E M IN IN G 1 1 /1 2 | 2014 17

FERROUS & NONFERROUS METALS

of the platinum-rich Bushveld Complex, that otherwise may remain unexploited as the relatively easily accessed Merensky reef is depleted and no longer available for blending with UG2.

Jubilee has announced a feasibility study for a 10 MW DC arc ConRoast smelter, paving the way for the construction of the first commercial (as opposed to experimental or research) ConRoast plant. This type of furnace is well suited to the processing of PGE concentrates from tailings dumps and other PGE-bearing materials from existing mines.

Fundamentally, the ConRoast process involves removing sulfur from metal sulfide concentrates prior to smelting in a DC arc furnace, which, under reducing conditions, produces molten iron droplets to capture PGEs, nickel, copper and cobalt. These droplets settle out into an iron alloy prior to refining the alloy and recovery and separation of the individual base metals from the PGMs. Sulfur dioxide is removed from the concentrate and captured in the roasting plant for conversion into sulfuric acid, a process that has obvious environmental advantages. ConRoast is therefore not limited by the sulfide content of metal ores and so can treat a wide range of ores. Also importantly, the DC arc furnace using ConRoast process is not CURRENT ECONOMIC adversely affected ENVIRONMENT Edwin Land (the inventor of by the chromite the Polaroid camera) once said, impurity in con“My personal philosophy is not centrate that charto undertake a project unless acterises platinum it is manifestly important and concentrates from nearly impossible”.

This approach to project the UG2, LG and selection seems to accord MG reefs, unlike well with the current set of the conventional challenges facing the PGM ‘six-in-line’ process. industry in general, and smaller Chromite in PGM companies in particular. The world economic crisis that concentrate is difcame to the fore in 2008 ficult to smelt in has curtailed a number of conventional lowotherwise promising mining er-temperature AC projects because of the low arc furnaces, as it availability of credit, the significant decline in the forms high-density, platinum price, and the high-melting-point strengthening rand (for an chrome spinels (a industry that incurs its costs in chrome compound rands, but earns its revenues of magnesia and in dollars).

If mining companies can silicate) that solidisurvive the ‘interesting times’ fy on furnace walls in which we are living, they will and in the slag. be well poised for significant This reduces furgrowth when the economy nace volumes and improves in the years ahead. efficiencies. As a result, conventional furnaces can only accept feeds containing 1.5% to 2.5% chromite. In contrast, the ConRoast process enables furnaces to accept any proportion of chromite.

It is by all accounts a great success, which is due to the leading and innovative research carried out by Rodney Jones and his team at Mintek. It certainly puts South Africa at the forefront of commercialised scientific development in mining and metallurgy. *References: Towards commercialisation of Mintek’s ConRoast process For platinum smelting, R.T. Jones, Pyrometallurgy Division, Mintek

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COEGA

Leading SA’s national metals beneficiation strategy

T

HE COEGA DEVELOPMENT Corporation (CDC) has announced ambitious plans for the expansion of metals beneficiation initiatives and metal sector investments in South Africa over the next decade.

The CDC will target bringing R28 billion in local and foreign investments to the IDZ, according to its newly unveiled 2014 to 2024 metals cluster strategy over the next 10 years.

An estimated 8 198 direct and 19 853 indirect jobs for the economy can potentially be created, according to CDC projections, and approximately 2 000 hectares, or 20% of the total IDZ land surface, will be dedicated to ferrous and nonferrous metal industrial activity.

According to Mogamad Sadick Davids, CDC metallurgy business development manager, several metal sector and mineral beneficiation projects are progressing well in the Coega IDZ with a “healthy investment pipeline.”

The manganese smelter, electro-mechanical component manufacturing plant, composite manufacturing and steel manufacturing of rail components will be converted in feasibility study stages during the 2014/2015 financial year and these projects are valued at R 13.6 billion.

Several projects worth R1.3 billion are currently in funding stages: including an iron ore plant, steel rolling mill and steel tube manufacturing plant.

“We have also received letters of intent from investors for a steel manufacturing plant and a manganese smelter collectively valued at R7.8 billion,” he says.

Davids adds that Agni Steels South Africa, a high-tech R400 million smelting facility, went into pilot production and is moving towards full production, in this year.

“We will intensify investor relation activities and are eager to pursue steel, stainless steel, rolling mills, manufacturing, ferrochrome, ferronickel and ferromanganese smelting projects over the next 10 years.

“Our metals clusters strategy is aligned to Department of Trade and Industry’s Industrial Policy Action Plan the Beneficiation Bill.”

Mogamad Sadick Davids, CDC metallurgy business development manager

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Socioeconomic considerations in mine closure I

In these modern times, mine closure and rehabilitation are integral components of the management obligations of any mining operation. But, it’s not just about restoring the land. It’s equally important to address the socioeconomic environment as well.

At its peak, the population of Kolmanskop included over 700 families living in the mining town, including about 300 German adults, 40 children and 800 Owambo

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N ITS SIMPLEST form, mine closure objectives aim to return land as closely as possible to its pre-mining conditions. While this is extremely important and ecologically optimal, we seem to place less of an emphasis on the socioeconomic aspects of mine closure and the impact on people because our focus has been channeled and shaped by the ‘green agenda’.

In speaking to Justin du Toit, an agricultural economist and project manager for Golder Associates, he places significant emphasis on the socioeconomic considerations of mine closure.

“When a mine is developed and put into operation it usually has a life of anything between 20 and 50 years, sometimes more.

During this time, as the mine invests in goods and services, a local town springs up from the resulting demand for goods and services to be situated close to the mine.

Over time, municipal infrastructure is developed, houses are built, people move in, a business district grows, albeit small, schools are built, the community puts down roots

and mine workers settle in to a routine that is repeated for the next few decades. Then the mine closes, the impact of which can be devastating, especially on the lives of the blue-collar workers and the middle class,” said du Toit.

Wikipedia lists more than 200 mining towns around the world that have become ghost towns. Millions of lives were impacted. Most of these mines closed during the 1960s when responsible mining was not legislated, or even considered by mine owners. In South Africa, it was just before and after the turn of the new millennium that mine closure legislation was promulgated and amended.

Even so, Southern Africa’s most famous deserted mining town is Kolmanskop, which was founded in 1908, in the middle of the Namibian diamond-fever era. The town, with its casino, a hospital and a school was slowly deserted right after the First World War, when diamond sales dropped.

“Today, South Africa’s legislation regarding mine closures and what constitutes responsible mining defines the ‘what’

MINE CLOSURE & REHABILITATION

adequately. But, like most things, the ‘how’ of it all is not well defined,” Du Toit adds.

Golder, who provides a comprehensive, integrated mine closure and rehabilitation consultancy service, has its own, unique, dual-focus approach that addresses both the ecological and socioeconomic aspects of a mine closure, and with equal emphasis.

However, as Du Toit points out, this does not just take in the mine and its immediate surrounds. It also looks at the extent to which the mine has a socioeconomic influence. This so-called zone of influence can extend to a radius of up to 100 kilometers or more from a mine.

Africa’s challenges The biggest challenge in South Africa, and other African countries, is that most mine workers do not have a Grade 12 education, let alone a post-matric qualification. This is a huge problem given the transformation of many economies to knowledge economies where a good education is essential. In many instances, agriculture’s contribution to the economy, especially in South Africa, has dropped down to a mere 2.5%. And, with a diminished manufacturing sector located in the major centres, far away from remotely located mines, miners who have lost their jobs due to a mine closure find themselves in a serious predicament.

In these instances, because of the poor education levels, the only solution to creating jobs is to look at labour-intensive agriculture and tourism, and to develop SMMEs. However, to be successful, this requires the mind of a social entrepreneur. What is a social entrepreneur? Business entrepreneurs typically measure performance in profit and return, but social entrepreneurs also take into account a positive return to society.

Social entrepreneurship typically furthers broad social, cultural, and environmental goals. In the instance of mine closures, social entrepreneurship must offer an altruistic form of entrepreneurship that focuses on the benefits that society may reap in terms of transforming social capital in a way that affects society positively.

Driving principles At the start of a project, Golder typically secures an agreement with mine management. The focus is on a mine closure plan to be developed, with a set of essential, overarching principles which enables rigorous sustainable development in optimising the social, environmental and economic benefits.

These principles, applied throughout the process of identifying potential

development projects, where communities In collaboration and agreement with the within the mine’s zone of influence are to be mine and other stakeholders, each of these beneficiaries, address the following aspects criteria is assigned a weighting which gives emphasis to certain criteria (such as alignof Golder's philosophy and should: • be relevant to community needs ment with this study’s overarching principles of sustainable development and fuand aspirations • build capacity amongst project partici- ture economic impact). This approach has pants for them to take ownership of, and assisted mines whom Golder has worked with to promote sustainable communities where appropriate manage their projects development by embed• provide direct benefits for local and responsible

ding the principles of sustainability into communities • provide for skills transfer and their planning, design and execution of development projects. knowledge transfer • be practical, implementable and sustainable Project After an initial proplanning and “When a mine ject concept is idenimplementation closes, the impact tified, the project is While the recomevaluated using a can be devastating, mendation is that classification tool to each of the develespecially on the assist in the selection opment projects lives of the blueand prioritisation of identified dureach socioeconomic ing the analysis collar workers and development compophase be considthe middle class.” nent. The tool uses a ered for impleJustin du Toit, agricultural simple multi-criteria mentation, the analysis approach to final say in which economist, Golder Associates rank projects based projects will be on their attractiveimplemented, ness scores. Scores and when, will are then allocated to ultimately be at a set of development the discretion of criteria on a scale of the mine and af1 to 10. The critefected communiria used to evaluate ties. It is also recthe attractiveness of ommended that each project can inmore detailed clude (for example): planning, prior to • alignment with the implementation, overarching princialso be carried ples of sustainable out to ensure that development these projects • alignment with have the greatest government policy/ chance of sucopportunities for cess, and positive partnership impact on the • future economic local and regionimpact (regional al economy.

GDP, production) Golder’s expewithin the mine’s zone of influence rience and successes in the field of mine • extent of direct and indirect closure planning, in both the ecological and employment creation socioeconomic environments, will assure • extent of local beneficiation mines of full compliance with legislative • practical implementation requirements and greatly reduce the social • project development/implementation impact when the mine does close. time • required subsidy to support the project’s operating expenditure until the project is self-supporting • need for buy-in from the mine • opportunities for private sector partnership. t +27 (0)11 254 4800 • www.golder.com IN SID E M IN IN G 1 1 /1 2 | 2014 21

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MINE CLOSURES

A long-term liability What is frequently underestimated is that mine closure liabilities are a serious and very real issue, both for miners themselves and their shareholders, not to mention for the broader South African society and economy. BY JON DUNCAN

I

T IS NO SECRET that the mining sector is currently plagued by a host of significant issues, with mine closure being just one of many. Given the current focus on labour issues and the increasing tensions surrounding continued and prolific strike action, mining closures and rehabilitation of these closures simply aren’t viewed as high-profile issues. Yet this attitude belies the serious nature of the risks arising from a lack of safe rehabilitation of closures, largely based on inefficiencies in this arena.

Mines not properly closed present a threat to the safe functioning of the The Big Hole in Kimberley is getting bigger due to its slopes failing. A section of the adjacent industrial area has been closed

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ecosystem, with the most urgent risk to this being ‘tailing’ such as acid mine drainage, and the implications of this pollution.

When it comes to end-land-use planning, Section 38(1)(d) of the MPRDA and Government Notice R.545 of the National Environmental Management Act (Nema) both state that mining operations should “as far as it is reasonably practicable, rehabilitate the environment affected by the prospecting or mining operations to its natural or predetermined state, or to a land use which conforms to the generally accepted principle of sustainable development.”

Legislation requires mines to submit an Environmental Management Plan as part of their mining applications. This plan requires the mines to include details on how

financial provision is to be made to rehabilitate the environmental impacts and to decommission the mine. The nature of the type of mine determines the extent of ongoing rehabilitation that is required.

However, the legislation around financial provisioning (liabilities) for mine closure rehabilitation is in a state of flux, which creates uncertainty for the industry and its investors – never a good thing for long-term social and economic sustainability.

Ongoing monitoring and financial modelling is a key activity for the appropriate decisions to be taken with the investment of assets and the funds expended on ongoing rehabilitation. The current approach to closure provisioning is largely undertaken through trusts, but in many cases these

MINE CLOSURE & REHABILITATION

ACID RAIN trusts are inadequately or over funded, with both outcomes being sub-optimal.

Yet a number of challenges exist which undermine the effort or the inclination of the industry to rehabilitate the impact of their mining activities. Firstly, as many miners and environmental and engineering specialists will attest to, determining the extent of the environmental impact of mining is not an exact science, while determining the extent of the life of a mine is also subjective.

What is more, new technologies are emerging which impact the nature of mining, its rehabilitation activities and the costs involved. Contingent liabilities caused by surrounding abandoned mines to the closed mine in question also contribute to uncertainty in this environment causing liabilities to be understated.

Closure certificates for rehabilitated abandoned sites seem to be rarely awarded. Without a certificate, the trust’s assets cannot be accessed. This serves as a deterrent for mining companies who need to find alternative funds for the rehabilitation before they can access the funds in the trust.

Annual financial statements of mining houses provide a snapshot of the closure provision for environmental rehabilitation and decommissioning as well as a summary of trust assets which have been set aside for final and premature closure. In many instances there is a shortfall between the assets and the liabilities, with the shortfall in many cases covered by a premature closure guarantee offered by a banking institution or a short-term insurer. Some mines avoid this by using a cashbased investment strategy, which may in the end lead to unnecessarily higher future payments made into the trust.

Financial provision therefore results in substantial assets that are set aside and it is mandatory for mines to ensure that the sum invested can support the ultimate objective of rehabilitation. The investment mandates for these assets are also a key consideration that needs to be taken into account in the context of impacting factors.

An organisation like Old Mutual Investment Group understands long-term liability and efficient mechanisms for provisioning, and we continue to bring this skill and financial insight to the mining sector in order to support the industry with more effective and efficient mine closure provisioning. We believe there is scope for great industry collaboration around these issues and for South Africa to learn from the US that has set up the Super Fund to deal with the clean-up and closure of hazardous sites.

It is important to note, when considering the challenges surrounding mining rehabilitation, that miners cannot operate in this sphere without a superior level of efficiency. It is this critical factor that needs to be foremost in all mining planning, and most importantly when it comes to financial provision. This is to ensure that the industry’s activities avoid negatively impacting the sustainability of our environment and its communities.

THE AUTHOR Jon Duncan, head of Responsible Investment at Old Mutual Investment Group

More important than carbon emissions Anthony Turton explains why sulphur

pollution is a bigger problem than carbon emissions.

O

NGOING NEGOTIA- The Olifants River drainage system is collapsing, TIONS following the specifically because initial Copenhagen of acidification conference focus on greenhouse gas emissions. Most greenhouse gases are derivatives of carbon and much is said about carbon in the context of global climate change.

What is left out of this discussion is sulfur, which, in my professional opinion, is far more important to the immediate and short-term future of the South African economy than carbon will ever be.

Sulfur is relevant in South Africa in two important manifestations. Atmospheric sulfur, in the form of sulfur dioxide, combines with moisture in clouds and falls to the ground as acid rain. Aquatic sulfur, in the form of sulfate salt, combines with water in underground mine voids and produces sulfuric acid, which in turn manifests as acid mine drainage. And, as parliament has just heard, it is a major problem.

THE AUTHOR Anthony Turton, a trained scientist specialising in water management Water Stewardship Council Trust

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Are mining rehabilitation What is frequently underestimated is that mine closure liabilities are a serious and very real issue, both for miners themselves and their shareholders, not to mention for the broader South African society and economy. BY BETSIE STRYDOM AND DUNCAN MCMEEKIN

M

INING COMPANIES are obliged to perform environmental rehabilitation of mining sites upon the termination, premature closure, decommissioning or final closure of the mine.

Section 37A of the Income Tax Act (ITA), 62 of 1968 serves to align tax policy with environmental regulation, and regulates mining rehabilitation funds created with the sole object of applying their property for the environmental rehabilitation of mining areas.

Section 37A of the ITA grants a tax deduction for payments made to dedicated mining rehabilitation funds and requires the funds to be strictly utilised in accordance with their objects. These rehabilitation funds are typically created as companies or trusts.

What happens though, when the rehabilitation fund is no longer needed, or has fulfilled its purpose and has surplus assets? What are the tax implications of amending or terminating such a rehabilitation fund?

Section 37A of the ITA was introduced in 2006. The primary object of this new Pure acid water (sulfuric)

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section was to grant a deduction from income tax to mining companies that pay cash into a rehabilitation fund which complies with Section 37A. Section 37A imposes strict rules in respect of rehabilitation funds, for example: The rehabilitation fund may only apply its assets for prescribed rehabilitation purposes (Section 37A 1a).

Once the rehabilitation has been completed to the satisfaction of the Minister of Minerals and Energy, the fund is obliged to transfer its assets to a similar company or trust, or to an account of a company or trust prescribed by the Minister and approved by the Commissioner for the South African Revenue Service (Section 37A 3).

Should the rehabilitation fund meet its liabilities, with sufficient assets to perform the required rehabilitation, the rehabilitation fund may transfer any surplus assets to another company or trust approved by the Commissioner (Section 37A 4).

Section 37A does not appear to cater for a situation where the rehabilitation fund has completed rehabilitation and has surplus assets, and the mining company does not have similar funds to which the assets can be transferred, or for the situation where the mining company wants

to transfer the assets of the rehabilitation fund to a similar fund, for value.

Section 37A 6, 7 and 8 impose income tax for contraventions of, or non-compliance with, Section 37A. In some cases, SARS possesses a discretion to reduce the income tax so imposed.

If the rehabilitation fund distributes its property for purposes other than the prescribed rehabilitation, in terms of Section 37A 7, the rehabilitation fund will have an inclusion in its taxable income for that year of assessment, of an amount equal to the market value of the property that was so distributed. The inclusion of the market value of the property so distributed, in the taxable income of the rehabilitation fund, is obligatory and SARS has no discretion.

Section 37A 8 is a catch-all provision that applies to any contravention of Section 37A. Where Section 37A has been contravened, the Commissioner may include: • an amount equal to twice the market value of all property held in the rehabilitation fund, on the date of contravention, in the rehabilitation fund’s taxable income • the amount that the mining company contributed to the rehabilitation fund (and claimed a tax deduction for), in the mining company’s income, to the extent that the property in the rehabilitation fund was directly or indirectly derived from cash paid to the rehabilitation fund.

Both the rehabilitation fund and the mining company pay tax where Section 37A 8 is triggered.

The inclusion of twice the market value of all property held in the rehabilitation fund on the date of contravention, in

MINE CLOSURE & REHABILITATION

funds still needed? for tax benefits in terms of Section 37A. It is likely that amendments to Section 37A rehabilitation funds could be dealt with in the following manner: Submissions will have to be made and reasons given to convince SARS why the ‘penalty’ catered for in Section 37A 8 should not be imposed. SARS is obliged to apply its mind and consider any submissions made, fairly. It is highly unlikely that SARS will waive the full amount as SARS may be of the view that the company has enjoyed the benefit of a tax deduction in terms of Section 37A. Termination or amendment of Furthermore, it is likely that SARS may the fund request that the assets in the rehabilitaShould the mining company wish to tertion fund be transferred to a similar acminate or amend the terms of the rehacount specified by the Minister (as conbilitation fund (for example to allow for templated in Section 37A 3b the transfer of funds to of the ITA). It is not clear, and a fund which is not a SecSARS is obliged to apply its mind seems unlikely, that SARS can tion 37A fund), the proinsist on such a transfer. visions of the constituand consider any submissions Any submissions made should tional documents, which made, fairly deal with the equity of the retypically are drafted in sultant position and show that line with Section 37A, the tax benefit enjoyed, as a will have to be amended result of the tax deduction, will in order to change the obbe offset by the inclusion in jects of the rehabilitation taxable income that will occur fund and the purpose for in terms of Section 37A 7. which the rehabilitation A transfer to a party other fund was established. than a Section 37A rehabiliThe directors or trustees tation fund could be accomof a rehabilitation fund plished by amending the conshall be bound to act in stitutional documents to allow accordance with the confor such a transfer. However, stitutional documents in Reprocessing mine dumps the risks of contravening the order to legally effect an to reclaim gold. Will this provisions of Section 37A are amendment or terminalead to more acid water? such that it would be prudent tion. If the rehabilitation to approach the Commissioner for prior termination of the rehabilitation fund fund is a trust, for example, the trustees l th t t t i ti f th h bilit ti f d t approval to amend the constitutional docwill need to be made with the approval of have to take care to act in terms of the uments of the rehabilitation fund and rethe Commissioner. Questions arise about trust deed. This principle was entrenched quest a decision on how SARS will exercise whether the Commissioner will consent to in the authoritative South African case its discretion in terms of Section 37A 8. an amendment of the constitutional docon the law of trusts, Land and AgriculturAn amendment of the constitutional uments of rehabilitation funds. The Comal Development Bank of SA v Parker and documents will most likely trigger the missioner should not be legally precluded others (2004) 4 All SA 261 (SCA), which penalties imposed by Section 37A 7 and/ from approving such an amendment to provides commentary on the invalidity of or 8. The ITA does not expressly prohibthe constitutional documents, but this trustees’ actions which are not in line with it the Commissioner to consent to such will depend on the facts of every case. the provisions of the trust instrument: amendments. The position appears to be The Commissioner cannot be be request“It vests in the trustees, and must be that it is possible for a mining company to ed to approve a breach of Section 37A, administered by them – and it is only terminate or amend the terms upon which but should be requested to approve the through the trustees, specified as in the the rehabilitation fund is founded, but amendments of the constitutional doctrust instrument, that the trust can act. there will probably be a tax cost. The exuments which have the effect that, after Who the trustees are, their number, how tent of the tax cost depends on how SARS the amendments, the rehabilitation fund they are appointed, and under what cirexercises its discretion. becomes a fund which no longer qualifies cumstances they have power to bind the taxable income, is discretionary, and the Commissioner has a discretion to reduce the amount of taxable income as he deems fit. Also, the inclusion in terms of Section 37A 7 is of an amount equal to the market value of the property that was distributed, whereas the inclusion in terms of Section 37A 8 is of twice the market value of the assets held in the trust on date of contravention. An inclusion in terms of Section 37A 7 is not discretionary, whereas the imposition of tax in terms of Section 37A 8 is.

trust estate are matters defined in the trust deed, which is the trust’s constitutive charter. Outside its provisions the trust estate cannot be bound.”

However, an amendment of the constitutional documents which places the object and transfer of assets outside of the ambit of Section 37A of the ITA will result in a contravention of Section 37A 3 and 4 (which specify to whom assets can be transferred to upon termination or closure) and the trustees or directors will have to take the tax and/or penalties imposed by Section 37A into account.

Since the constitutional documents of the rehabilitation fund will initially be drafted to comply with Section 37A, it can be assumed that any amendment or

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Mining impact on groundwater Identifying, mapping and modelling contamination infiltration into and through mine workings – especially into groundwater – is a critical and much-needed function and sadly one that is ignored in many instances.

BY VAL KOFOED AND MIKE JESSOP

O

CASE STUDY 1 NE OF THE greatest chalApplication of the technology lenges facing the mining The application of the methodology is Tailings dam seepage industry, in regard to both based on the principle that water ininvestigation active mining practices and filtrating and flowing through or near eventual mine closure, is the long-term mine workings substantially increases Background liabilities required in monitoring and the conductivity of the earthen materials A mining company with a large tailings protecting groundwater. When a mine is through which it flows. dam was required to show that its imclosed, the potential threat to air quality As a signature electric current is bi- poundment and seepage collection sysimmediately stops. tem were controlling Following reclamaand capturing all seeption of the land (covage as designed, and ering, contouring and that no tailings water re-seeding), the mine was escaping the syseventually fades in tem. An accurate unwith the surrounding derstanding of seepage scenery. Groundwaconditions was critical ter quality, however, in proving to regulators When a mine is closed, can be a perpetual that the tailings did not groundwater quality can be a concern. pose a threat to the surUnderstanding the rounding ecosystem. perpetual concern source and distribution of groundwater Approach into and through To address the issue, mine workings is bethe methodology was coming increasingly employed by energisimportant for the ing the tailings pond successful operation with a signature elecand eventual closure tric current to track of a mine. This paper routes of escape from considers a high-speed, minimally invaased to flow between strategically placed the impoundment. The investigation prosive mapping technology called the Wilelectrodes (located up-gradient and vided insight into seepage flow patterns lowstick method. down-gradient of the targeted study through, beneath and around the imIt has been specifically designed for area), it concentrates in the zones of pounding structure, including a natural mapping preferential flow paths or arhigher transport porosity where ground- groundwater source downstream of the eas of highest interconnected porosity water preferentially flows through and/or dam’s right abutment. (transport porosity) within the subAn electric current of specific signabeneath the mine. surface. The method has proven effecMagnetic fields generated from the ture frequency was applied to energise tive in delineating and characterising distribution of electric current can then between an up-gradient electrode in the subsurface aqueous systems in many be interpreted and modelled to charac- tailings pond and a down-gradient eleccomplex hydrogeologic settings for terise how and where groundwater pref- trode in a monitoring well located downnumerous mining clients in a variety erentially infiltrates and flows through stream of the seepage collection system. of applications.

As electric current flowed between the a mine.

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MINE CLOSURE & REHABILITATION

electrodes, it generated a signature magnetic field that was measured over the study area. The methodology also incorporates a prediction of the magnetic field response for any given electrode configuration assuming a homogenous subsurface. The measured magnetic field can then be compared to this ‘uniform’ case distribution to bring out any heterogeneity or preferential flow of electric current.

This processed data is used to create a ‘ratio response map’ and it is the basis for generating a two-dimensional (surface level) interpretation of preferential flow paths. The data is then processed through an inversion algorithm to generate a 3D model of electric current distribution termed an ECD model. The ECD information is presented within the framework of a 3D site model, a powerful tool to explore and explain how electric current (interpreted as tailings water in this case) potentially escapes the impoundment.

Results A preferential flow path was identified beneath the tailings pond’s starter dam and between the left and right abutment cut-off walls, which do not extend beneath the starter dam. As tailings water seeps beneath the starter dam’s upstream toe and into the weathered bedrock, it converges and migrates beneath the dam, FIGURE 1 Typical horizontal dipole configuration

slightly offset of the rock underdrain system. It then turns towards the rock underdrain and flows out at the toe and into the seepage collection pond. This interpretation fits with known seepage collection data. At the same time, there was no evidence of seepage in the abutments or anywhere else that might bypass the seepage collection system. The dam’s underdrain and seepage collection systems were found to be working as designed – effectively capturing seepage from the main dam.

Summary The seepage investigation provided the mine owner with new insights and intelligence regarding seepage conditions, and the information was used to meet obligations required of regulators. The survey results also provided a baseline to compare future conditions.

CASE STUDY 2 Acid rock drainage investigation Background As part of mine closure operations, groundwater conditions were closely monitored at a site where a large waste rock dump lay partially on undisturbed till soil and partially on graded till soil. Acid rock drainage (ARD) was observed seeping from the waste rock and

a collection system and treatment plant were installed. The cost to collect and treat ARD was significant. In an effort to reduce ARD volume, the slopes of the waste rock dump were graded and covered with a 0.5 m thick compacted silty clay cap and a 0.3 m uncompacted till layer, which was then seeded. This was done to minimise erosion, reduce water and oxygen transfer to the waste rock from a meteoric source, and thereby reduce ARD. When the ARD volume remained higher than expected, however, the focus shifted to groundwater sources potentially infiltrating the waste rock dump.

Approach to the work The methodology was employed to detect potential groundwater sources up-gradient of the dump. A secondary objective was to see if the cover was performing as designed by targeting a small area of the cap. Electrodes were strategically located in monitoring wells in contact with the upstream groundwater and the downstream ARD-contaminated water.

Figure 1 presents a cross-sectional sketch of the horizontal dipole configuration used for the investigation.

Results Two sources of groundwater infiltration were identified. There was no evidence of excessive infiltration through the cap.

Based on electric current flow patterns,

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groundwater from up-gradient sources was concentrating in preferential flow along bedrock fractures and entering the waste rock dump at two locations.

Figure 2 shows a profile section and conceptual sketch along one of the two groundwater sources, wherein locations of the up-gradient and down-gradient electrodes are noted as well as lithologic units through which electric current and groundwater flows.

Modelling results showed a transition from concentrated flow to more uniform or dispersive flow as groundwater spread out through the crushed backfill material. This transition begins at the point represented by the black dashed line in Figure 2.

As electric current concentrates in preferential flow paths upstream of the transition point, it flows mostly beneath the till layer, which is sandwiched between the bedrock and waste dump material.

Beyond the point of transition, the electric current (and its groundwater host) begins to pass through the till material and reach the interface between the till and waste rock. It also spreads out in lateral dispersive fashion along the interface and migrates towards the toe and down-gradient electrode. It is this latter part of the journey where most of the ARD is generated.

FIGURE 2 Profile section, groundwater

source #1

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Summary

Results

The investigation results were used to make informed, guided and cost-effective decisions regarding how to prevent groundwater from infiltrating the waste dump and generating excessive ARD.

The electric current distribution between the pad and monitoring well was uniform, and no preferential paths were detected. Consequently, it was believed that the increased nitrates were the result of a nearby spill that had occurred sometime previous to the reported increase. The regulators agreed not to impose remedial action but to continue monitoring.

CASE STUDY 3 HDPE liner investigation Background Due to a gradual increase in nitrate levels in a monitoring well located down-gradient of a heap leach pad, and insufficient data to prove or disprove the potential for leakage through the pad’s HDPE liner, the regulatory agency and mine owner elected to employ the methodology to explore whether any preferential flow paths exist between the monitoring well and heap leach pad. Because the method makes possible a quick and accurate assessment, it allows regulators and industry professionals in such cases to come together and work out an equitable solution, as was demonstrated by this project.

Approach to the work Electrodes were placed on the heap leach pad and in the down-gradient monitoring well where nitrate levels were detected above the allowable limit. The objective was to detect any paths or zones of preferential flow that would suggest a breach in the HDPE liner or any kind of connection from the pad to the monitoring well.

Conclusion The methodology has proven effective in characterising subsurface aqueous systems in many complex hydrogeologic settings for numerous mining operations. The method provides a quick and cost-effective tool to focus remedial efforts, drilling, and/or to minimise long-term liabilities associated with monitoring and protecting groundwater. The methodology is providing industry-changing value with regard to groundwater characterisation.

THE AUTHORS Val Kofoed PE President, Willowstick Technologies

Mike Jessop PGp Senior staff geophysicist, Willowstick Technologies

MINE CLOSURE & REHABILITATION

Clamping down on illegal mining The Council for Geoscience is to close 45 open mine shafts in an effort to stop illegal mining in disused mines.

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ITH THE BODY count of murdered illegal miners, or ‘zama zamas’ as they are colloquially referred to, rising steadily, the Department of Mineral Resources, through the Council for Geoscience (CGS), has taken firm steps to prevent illegal mining and to protect communities who live near the derelict and ownerless mines of Gauteng, Limpopo and Mpumalanga.

Speaking during a CGS presentation to Parliament’s Portfolio Committee on Mineral Resources in Pretoria, water and environmental manager at the CGS Mosidi Makgae says, “In Gauteng, we are prioritising areas with shafts in the informal settlements because they pose an immediate danger.”

The presentation by the Department of Mineral Resources has revealed that illegal mining had a negative impact on the country’s economy and resulted in a significant loss of revenue for the state and mines.

“According to a 2007 study, it was found that close to 10% (R5.6 billion) of gold production was stolen and smuggled out of the country annually,” a report presented

by David Msiza, a chief inspector from the Department of Mineral Resources, says.

Makgae says the council had appointed engineering service providers, who would supply innovative designs to try to beat illegal miners at their own game.

“To this date, we have managed to close about 146 sites and out of the 146 sites, 11 of those have been reopened by illegal miners,” she says.

Makgae says field workers, who were

tasked with closing the shafts, had a risky job because they had physical encounters with the illegal miners.

“When we appoint contractors to close the shafts, it’s a fight between the contractors and the illegal miners because they are saying ‘this is our bread and butter and you taking that away from us’,” she says.

Msiza says illegal mining was carried

A typical unsecured and disused mine targeted by illegal miners

such as strengthening access control and security measures at mines.

Other measures that have been put in place were the rehabilitation of derelict and ownerless mines. Msiza says open holes, shafts and openings were continuously identified and sealed by the Department of “Illegal mining has Mineral Resources, had a negative CGS and mining impact on the companies.

Even though the country’s economy.” department had Mosidi Makgae, water and challenges when environmental manager, CGS dealing with illegal mining, it had made some achievements. The departout by national and international orment had sealed 126 open shafts and ganised crime syndicates targeting the holes in Gauteng. mining sector.

In March, a mine manager was arrested He says the syndicates were highly organafter he was found to be in possession of ised, dangerous, well financed and com1.3 kg of gold believed to have been 80% plex. Illegal mining was fuelled by mine pure and worth R500 000. closures, liquidations and self-enrichment.

In June this year, Sibanye Gold employThe Department of Mineral Resources ees were arrested at Driefontein Gold Plant established the Gauteng Stakeholder Fofor alleged gold theft. It is believed that the rum, which has implemented a number employees are part of a syndicate. of interventions to prevent illegal mining, IN SID E M IN IN G 1 1 /1 2 | 2014 29

MINE CLOSURE & REHABILITATION

Retaining land value after closure Carefully considered environmental plans can take future quarries through their useful lives to become highly sought-after entertainment centres, racetracks, shopping centres or even business and residential parks.

Deep excavations of quarries can be turned into useful property developments

I

F A LARGE-SCALE quarry is conceived and planned correctly, it can be profitably operated for many years or decades with the ultimate goal of turning it into an asset for society and especially for surrounding communities.

This type of ‘second-life’ usage should be considered for all quarries and can be integrated into environmental management plans (EMP) as part of the overall environmental rehabilitation of the property.

to enrich surrounding areas and even to solve problems of urbanising and industrialising populations, such as landfills etc.

He added that Aspasa has done much to change the paradigm of quarry rehabilitation by assisting government to regulate the industry, as well as through its initiative to audit members for environmental compliance on an annual basis. More recently, the introduction of Aspasa’s own environmental management system (based on ISO 14001) helped quarries to align themselves with modern-day environmental management requirements.

Downstream benefits Potential value This is according to environmental consultant Alan Cluett who was speaking at the KwaZulu-Natal regional meeting of the Aggregate and Sand Producer’s Association of Southern Africa (Aspasa) recently. He says that quarries in urban areas especially could be developed to become sought-after properties and that more rural quarries had potential for other types of uses such as farming, water storage etc.

Regions such as KwaZulu-Natal (and other parts of the country), with beautiful landscapes and a high percentage of income derived as a result of tourism, can especially make use of exhausted quarries

30 INS I DE MI NI NG 1 1 / 1 2 | 2 0 1 4

“This shows that any quarry’s EMP need not be a hindrance, but should rather be a basis for the responsible reusage of the land. If followed correctly, it can save quarry owners a fortune and can leave the land in a state that is highly saleable.

“Beyond guiding quarries on land use, EMPs also serve as a record of the operation’s usage rights, responsibilities and compliance. In the event of an environmental accident, these management systems can also assist quarry owners in court and show how management was conducted before the event rather than after,” says Alan.

He added that management of a quarry needed to be realistic as an EMP is legally

binding and closure plans need to be adhered to. Provided environmental stipulations are met, and the public is extensively consulted with prior to plans being finalised, then there is no reason why quarry owners cannot and should not plan quarries to have a useful life after mining operations have ceased.

Into the future He says that already some forward-thinking quarries overseas and in South Africa had already adopted this approach and designed environmental management and quarry closure plans that allowed the quarries to be developed into various types of land uses. Examples locally include: Tyger Falls Waterfront in the Western Cape, Eagle Canyon in Gauteng and the Quarry Centre in KwaZulu-Natal.

To conclude, the following are needed: • reviewing existing quarry plans and adapting them to include concurrent usage, rehabilitation and closure plans that are centred on further development of the property upon the completion of quarrying • working with communities to find out their future requirements and if the type of land use proposed is acceptable and inline with their requirements • working with local government and municipalities to get inclusion in Integrated Development Plans and regional plans • developing partnerships now with authorities and development companies to plan and get the buy in of potential stakeholders and financiers • improving opinions of neighbours, communities and authorities about operational quarries and educate them on the importance of sand and stone in the development of our country and their region. Show people how future plans for the property can benefit them.

PROJECTS IN AFRICA

Orthoimagery

The purpose of orthoimagery is to enable us to clearly and accurately see the world below.

H

IGH-RESOLUTION orthoimagery is used in environmental analysis and compliance documentation, as well as in the compilation of GIS-based infrastructure and operations management

systems. This is particularly relevant to mining operations.

Distortions can creep into aerial photographs, and that’s where orthorectification comes in. This is a computerised process wherein aerial imagery is converted to a uniform scale and an orthogonal view of the earth surface is created, hence it is called orthoimagery.

Optical distortion and perspective are removed, and real-world coordinates are assigned to each image pixel. Therefore, the location of any feature in the image can be instantly determined, distances and areas computed, and feature relationships interpreted.

Orthoimagery is extremely useful in all stages of project planning and design as well as other activities such as resource management and municipal facilities management. A major benefit of orthoimagery is that it embodies far more information than the planimetric abstractions of typical maps. Orthoimagery shows everything that is there to be seen, from built feature details to vegetation characteristics and land use.

IN SID E M IN IN G 1 1 /1 2 | 2014 31

LEGAL

Zambia’s exploration and mining policies

Because Zambia is a mining country, and energy is the engine for growth of its economy, the focus of this paper will be on the investment potential and attractiveness of Zambia’s mining and energy sectors. BY CHRISTOPHER YALUMA

Z

AMBIA IS AMONG the major mining countries on the continent of Africa, with an average growth of 5% per annum over the last ten years. The contribution of mining to the gross domestic product (GDP) in the past 10 years averaged 10.19%. The vision of the government is to increase the contribution of mining to GDP to 20% in the next five years. To achieve this, a number of measures are being implemented.

These include:

Adoption of clear mining policies The Mineral Resources Development Policy was launched in 2013. The policy clearly outlines government position on the development of mineral resources in the country. The policy is aimed at facilitating the development of a mining industry that generates benefits for the Zambian people while at the same time rewarding the investors.

The mineral potential of Zambia is not fully exploited. We realise that to unlock this potential, foreign direct investment is required on one hand and support of the local communities on the other hand. Hence the policy ensures fair benefits for the local communities and rewards for the investors. In this setup, the role of government

32 INSI DE MI NI NG 1 1 / 1 2 | 2 0 1 4

remains that of ensuring an enabling environment for the development of a vibrant and orderly mining industry.

Revision of the legal framework The principal legislation governing the mining industry in Zambia is the Mines and Minerals Development Act 7 of 2008, which is based on the government’s commitment to the application of modern prin-

The mineral potential of Zambia is not fully exploited. We realise that to unlock this potential, foreign direct investment is required ciples of transparency and accountability in the management of mineral resources. The Act broadly deals with licensing and regulation of mining activities. The revision of the Act has reached an advanced stage.

The aim for revising the Act is to align it with the policy, address the inadequacies identified by both the mining industry and the country relating to the optimum

development of mineral resources, and to enhance the regulation and monitoring of the mining industry to improve transparency in the industry and develop confidence among all the sector players. Some of the identified challenges that the revision of the Act will address are: • unnecessary bureaucracy in the issuance of mining rights • inadequate size and duration of prospecting licences • lack of provisions to retain a tenement in situations where progression to mine development becomes impossible due to adverse economic conditions or technological constraints.

Provision of support infrastructure To support the growth of the mining industry and other sectors of the economy, the government is addressing the challenge of inadequate infrastructure, energy and transport in particular.

Zambia is in a hurry to increase power to meet growing demand. The demand for energy, electricity in particular, has been growing at an average rate of 3% per annum mainly due to the increased economic activity in the country especially in the agriculture, manufacturing and mining sectors, as well as increased activity in the region.

LEGAL

OPPOSITE Kansanshi Copper PHOTO: ABB

Demand for the other forms of energy, which include renewable energies, has also seen significant growth in the recent years.

Zambia has about 6 000 MW hydropower potential, out of which only about 2 393 MW has been developed. To increase power generation capacity, a number of projects are being undertaken. These include: • 360 MW Kariba North Bank extension • the 750 MW Kafue Gorge Lower Hydro; this project is critical for Zambia and the Southern African Power Pool • the 120 MW Itezhi-tezhi Hydro Power Project • the 300 MW to 900 MW thermal power plant by Maamba Collieries.

There are also power generation projects open for investment that are predominantly hydro and include: • Kafue Gorge Lower on Kafue River with an estimated 750 MW estimated capacity • Batoka Gorge on Zambezi River with an estimated capacity of 1 600 MW • Devils Gorge on Zambezi River with estimated capacity of 800 MW • Mpata Gorge with an estimated capacity of 540 MW. Projects open for investment are not limited to generation development; there are a number of transmission projects that are currently taking place in Zambia. Among the transmission projects, we have greenfield projects as well as the upgrade of existing transmission lines in order to improve the capacity of the transmission system to deliver the huge amounts of electrical power to consumers across the country and some to our neighbours.

In terms of transport infrastructure, Zambia has embarked on an ambitious development programme. A number of road projects within districts and across the country are being implemented through the Link Zambia 8000. In addition, rehabilitation of Zambia’s rail network commenced and is progressing well.

There are also plans to open up regional corridors through the building and revamping of old railway lines. Of great interest are the Nacala and Beira Corridors to the East, and the Lobito Corridor to the West.

The continued increase in exploration and mining activities being

experienced attests to the country’s untapped mineral potential and favourable investment climate.

In the past few years, a number of expansion projects at existing mines have taken place and new mines have come on board resulting in the increase in mineral production. Copper production in the past three years increased by 8% from 677 604 tonnes in 2011 to 759 784 tonnes in 2013. It is projected to increase to over one million tonnes by 2015.

Mining has been Zambia’s engine of economic growth and will continue to offer great investment opportunities. New mining fronts for copper and nickel have opened up apart from the traditional copperbelt. There is still potential within the 40% of the country that is geologically unmapped. Investment in this area will unlock the unknown potential for various minerals.

Exploration for oil and gas is another area where government is encouraging investment. The petroleum potential in Zambia remains unexplored. Based on the results of the preliminary work conducted, the government demarcated the country into blocks, some of which were reserved for government.

The government recently granted nine licences to successful bidders and

will be announcing a new round in the near future.

Zambia also offers investment opportunities in value-addition industries such as the iron and steel industry, cement and lime production, as well as fertiliser manufacturing.

The investment climate in Zambia remains favourable. The government continues to be committed to ensuring a conducive investment climate that promotes both local and foreign investment.

Zambia has potential and is ready for investment. Zambia is a stable investment destination with political stability and peace, good mining sector regulations and offers vast investment opportunities ranging from exploration to value addition. To a serious investor in mining and energy, Zambia is generally a low-risk investment destination and has attracted significant foreign direct investment in the recent past.

The investment Zambia is looking for is one which will ensure a win-win situation.

THE SPEAKER Honourable Christopher Yaluma Minister of Mines, Energy and Water Development, Zambia

FIGURE 2 Geological setting of the Zambian Copperbelt and the distribution of strata-bound, sedimenthosted copper deposits

IN SID E M IN IN G 1 1 /1 2 | 2014 33

ENERGY

The energy

to the site, which means it hardly ever supplies 100% of power on-site. This means that even in energy-efficient buildings, a portion of the energy will come from Eskom, which leaves the site exposed in the event of a blackout. It is thus imperative to work with an energy partner that can customise your solution to meet specific needs at the most affordable cost.”

Another popular solution in the event of a blackout is generators, but these are a costly energy source at approximately R5 per kWh in comparison to R1.10 per kWh from Eskom. “When selecting a generator, it is important to use a reputable supplier who will take responsibility for the maintenance of the generator and ensure that the maximum demand for the site will be proved by the Private Sector Energy Effisufficiently serviced. ciency programme, which falls under the Often, the most efficient solution will National Business Initiative umbrella that combine renewable and backup (generhas R150 million worth of foreign funding ator) energy solutions and incorporate available for development of energy effithese into a business’s existing infrastrucciency awareness and projects.” ture, according to De Waal. This methodolAlternative energy sources must be utiogy minimises the risk of business interlised strategically to minimise cost durruption at the most affordable cost. ing a blackout, says De Waal. “Renewable “In order to reduce sources of energy, reliance on Eskom for such as solar and “The full financial energy requirements, wind, can facileffect of load business owners itate processes should ask a reliain the event of a shedding... cost ble energy-effi ciency blackout.” the economy partner to conduct an However, he says, a staggering energy audit to ensure the nature of rethat energy processes newable energy is R15 billion.” and solutions can be irregular as it deManie de Waal, head of sales, Energy Partners implemented for optipends heavily on mal efficiency. external sources This is particularly and storage techimportant for businology is still very nesses that rely heavexpensive in South ily on electricity for Africa. “Typically key processes such as renewable sourcmanufacture, agricules do not form the ture and mining,” conbaseload, but are cludes De Waal. specified according

imperative Eskom’s decline highlights the need for alternative energy sources for South African businesses.

E

SKOM’S recent request for its customers to reduce energy consumption, even if it means reducing production, together with ordered blackouts, poses a real threat to the growth of corporate South Africa.

This is according to Manie de Waal, head of sales at Energy Partners, a leading energy solutions provider in South Africa, who says that, together with affecting national development, Eskom’s current inability to deliver uninterrupted electricity has a massive impact on companies’ annual earnings. “The full financial effect of load shedding is often hidden as it is ‘revenue not earned’ as opposed to actual financial losses. In 2008, the National Energy Regulator of South Africa (Nersa) reported that it had cost South Africa’s economy a staggering R15 billion.”

De Waal says that there is a direct link between economic growth and an adequate energy supply, which means that corporate South Africa must move collectively towards implementing feasible solutions to ensure continued foreign investment and national growth. “There is already considerable interest and foreign investment into South Africa’s energy efficiency, as

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TECHNOLOGY

Measuring productivity

T

HE 2014 Joburg Indaba once again raised the issue of productivity, especially with regards to labour, but capital equipment, which costs millions, also needs to be productive.

It was Peter Drucker, American management consultant, educator and author – whose writings contributed to the philosophical and practical foundations of the modern business corporation – who said, “If you can’t measure it, you can’t manage it.”

Innovative technology company Booyco Electronics’ state-ofthe-art onboard monitoring device can be fitted to underground mining equipment to measure a spectrum of parameters that affect both equipment and operator. These include detailed, accurate and real-time data indicating the operating, standing and idle hours of vehicles, the running hours of drill rigs and roof bolter machines, as well as machine abuse.

The ability to monitor the percussion hours of a piece of machinery provides management with detailed information on how many hours the drill bit worked, as well as the actual production hours of the machine when the percussion was running, and the amount of vibration to which the operator was subjected.

To avoid driver fatigue, this innovative onboard monitoring technology can also be configured to automatically shut down machines at preset intervals and only allow them to be restarted once the rest period is over.

Detailed reports of the various data are accessed via a fixed reader connected to a fibre-optic backbone that is linked to a server on the surface, or via a portable tablet or PC fitted with a reader.

Booyco Electronics is a single-source market leader that supplies quality, specialised electronic safety equipment, including collision intervention systems. Its range of reliable, accurate warning, locating and monitoring systems is engineered to operate in the harsh African conditions.

TOP Booyco Electronics’ state-of-the-art onboard monitoring device offers accurate real-time data LEFT The device can measure a spectrum of parameters and provides detailed monitoring information

I N S I D E M I N I N G 1 1 / 1 2 | 2 0 14 35

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

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

+2711 823 6842 • www.booyco-electronics.co.za

WE NEVER STOP With reverse circulation capabilities added to the DM45 and DML, it further emphasizes the flexibility of Atlas Copco’s blasthole drills.

Mines around the world are bringing the added dimension of in-pit grade control with the addition of the Reverse Circulation (RC) kit. In addition to being ordered on a new machine, it also has the flexibility to be retrofitted in the field on the DM45 and DML where sampling and in-pit grade control are required in addition to production drilling. To learn more about what Atlas Copco’s reverse circulation kit has to offer, visit us at www.atlascopco.co.za/blastholedrills.

Atlas Copco South Africa Phone: +27 11 821 9000 Fax: +27 11 821 9202/9246 Innes Road, Jet Park, Boksburg, 1459 www.atlascopco.co.za

TECHNOLOGY

35% energy saving Variable-speed drive (VSD) compressor technology, one of the niftiest innovations of our time, is the key to sustainable, energy-efficient operation and low cost of ownership in mining.

W

ITH DECLINING global energy resources and escalating electricity costs, 21st century mining around the world faces similar challenges and shares the same objectives – to minimise costs and increase productivity.

This compels mines to be quite discerning and install equipment that combines high performance with efficient operation for optimum productivity and the lowest possible operational costs.

To assist mines in meeting these objectives, Atlas Copco focuses on end-to-end energy-efficient operation in the development and design of its compressors.

Besides quality, the focal point is to minimise the cost of each cubic metre of compressed air produced. And, to be able to supply compressors that deliver bestcase scenarios for reliability, performance and efficiency.

VSD (frequency-controlled) technology forms an integral part of Atlas Copco’s energy-saving drive, which is to achieve maximum energy efficiency and sustainable productivity.

The company’s range of oil-injected rotary-screw compressors, the GA VSD (GA 5-90 kW) with world-class free air delivery (FAD) and the GA 90-500 kW for larger air requirements, as well as the more recent, highly compact 7-37 GA VSD+, clearly reflect this drive towards achieving optimum efficiency during compressed-air delivery.

“Energy consumption typically represents over 70% of a compressor’s life-cycle cost, which opens up tremendous energy saving opportunities,” according to Atlas Copco Compressor Technique’s business line managers for the Oil-free Air and Industrial Air divisions, respectively, Pieter van Wyk and Charl Ackerman.

Atlas Copco’s GA 315 VSD FF compressor delivers sustainable, energyefficient operation

Giving a broad outline of VSD, a technology pioneered by Atlas Copco in 1994, Van Wyk confirms that energy savings of up to 35% can be realised. “The VSD compressor perfectly matches air supply to air demand in processes where air demand profiles fluctuate. By varying the speed drive of the drive motor, the compressor follows fluctuation in production demand; as air demand declines or is reduced, the GA VSD lowers the delivered flow and consequently the power consumption.”

Van Wyk adds that motor speed regulation is the most efficient compressor control method where air demand varies “because the inefficient transition period between full and no load is eliminated, which avoids excessive off-load power consumption. Maintaining the net pressure band within 0.10 bar, greatly reduces the overall average working pressure and energy costs.” Soft start will lend further flexibility as gradual motor ramp-up avoids electricity surges. Reduced CO2 emissions are another benefit offered by VSD technology.

Ackerman points out that the most efficient compressor package incorporates optimisation of all the compressor elements (oil-injection, flow and temperature) to maximise output and minimise losses. In the development of the GA VSD, substantial efforts were made

to reduce all types of losses, whether flow-related, mechanical or electrical.

The highly compact oil-injected rotary screw 7-37 GA VSD compressor range, introduced by Atlas Copco in April 2013, serves as an excellent example where Atlas Copco evaluated every part in the compressor to ensure across-the-board optimisation: • A more efficient fan, a robust air intake system, the elimination of all blow-off losses, and the best electronic components together with the new drive train, add up to breakthrough energy efficiency. Better performances are delivered, even at full load, while consuming on average 50% less energy compared to a traditional idling compressor.

• Available from 7 kW to 37 kW, the GA VSD is an additional 15% more efficient and operates at lower noise levels. The range also offers a leap forward in FAD with improvements of up to 12%. The GA VSD has been completely in-house developed and brings together all the company's expertise and know-how on energy-efficient compressor technology. The compressor contributes significantly to the green economy needs as this innovation enables all compressor users to switch over to variable-speed drive compressors – an important step towards a more sustainable industry.

• Last of all, regular service and maintenance by skilled technicians using the right tools and genuine parts is essential for ensuring optimum, reliable and efficient compressor performance and sustainable productivity.

IN SID E M IN IN G 1 1 /1 2 | 2014 37

Tega offers value added consultancy services and solutions

in Mineral BeneďŹ ciation, Bulk Solids handling, Wear and Abrasion customised to suit speciďŹ c applications.

With focus on core engineering applications in the Mining and Mineral Processing Industry, Steel plants, Power, Port and Cement Industries.

Tega Industries (South Africa) Pty Ltd P.O Box 17260, Benoni West, 1503, South Africa, Phone: (011) 421 - 9916/ 7, 421 - 6714, 421 - 6761, Fax: (011) 845 1472, Email: info@tegaindustries.co.za, www.tegaindustries.com

TM

TOTAL : Solution

TECHNOLOGY

Focus on processing efficiency The overriding message coming out of Electra Mining 2014 was the need to improve operating efficiencies and productivity, especially in minerals processing plants.

S

PEAKING AFTER this year’s Electra Mining exhibition, which was held in Johannesburg recently, Vishal Gautam, of Tega Industries South Africa, says: “The majority of visitors at the company’s stand were interested in finding complete solutions to improve aspects, if not all, of their processing requirements.

“It was clear that a trend was emerging where mines are demanding more from their suppliers and seeking assistance from companies, like Tega Industries, who offer complete materials handling solutions, to help them achieve their efficiency objectives.”

Rather than shop around for mill liners from one supplier, screens from another and conveyor components from yet another, and so on, mines are looking for solutions where all aspects of a process are viewed holistically and optimised through properly engineered solutions. However, it will be incumbent upon the supplier to gain and maintain the relationship on a mutually beneficial basis.

Mines are looking for solutions where all aspects of a process are viewed holistically and optimised through properly engineered solutions

Showcasing diversity “Electra Mining’s annual exhibition is extremely important to Africa’s mining industry and it was an opportunity for us to show our full product range and introduce the mining fraternity to our products and demonstrate our capabilities. As a result of the increasing demand for reliable and efficient solutions, we invested in two stands and were able to exhibit all of our product solutions and introduce our product

experts, who are absolutely crucial to ongoing support requirements.

“Representatives from our branches in Zambia and Ghana were also present to interact with the many African visitors to the show and we were also able to introduce visitors to representatives from our international operations, such as India and Australia, as well.

“The kind of global expertise we are able to bring to the fore is exactly what the market is looking for, and needs.

While mines are always looking for new

technologies to improve efficiencies, they are also looking for solutions that have been tried and tested in other parts of the world,” says Gautam.

“In the end, we had nearly 1 000 visitors who interacted with us at our stand.

It provided us with a unique opportunity to guage and understand the needs and wants of the mining industry, which is so important to us in delivering customer satisfaction, through the provision of the right product, at the right price and at the right time,” Gautam concludes.

IN SID E M IN IN G 1 1 /1 2 | 2014 39

Excellent Minerals Solutions

WARMANÂŽ Centrifugal Slurry Pumps ENVIROTECHÂŽ Centrifugal Slurry Pumps ISOGATEÂŽ Slurry Valves

Lower your operational costs with the Weir Minerals Solution In slurry and dewatering pumping, processing and control applications where the cost of ownership often outweighs capital cost as a priority, we help our customers address such issues CU NQPIGXKV[ ECRCEKV[ GHȨ EKGPE[ QH operation and maintenance.

Expertise where it counts

WarmanÂŽ slurry and EnvirotechÂŽ dewatering pumps are among the worldâ&#x20AC;&#x2122;s most comprehensive range of pumps for use in mining, chemical and industrial applications. These pumps are designed for ultra heavy duty applications such as mill discharge, process plant and tailings, high pressure pipelines, as well as other speciality applications.

Robust design and rugged heavy-duty construction, the IsogateÂŽ slurry knife gate valve is designed for long life and high reliability.

The IsogateÂŽ valve range now also includes Autoballâ&#x201E;˘ 3 way check valves, swing check valves, and a diverse range of mechanical and pneumatic pinch valves.

Copyright Š2012, Weir Minerals Africa (Pty) Ltd. All rights reserved.

WARMAN is a registered trademark of Weir Minerals Australia Ltd and Weir Group African IP Ltd; ISOGATE is a registered trademark of Weir do Brasil Ltda; AUTOBALL is a trademark of Weir Minerals Australia Ltd.

For more information contact us on: +27 (0)11 9292600 www.weirminerals.com

TECHNOLOGY

Expanding into new technology The Weir Group has entered into an agreement to acquire Trio Engineered Products – a Chinese-American manufacturer of crushing and separation equipment for the mining and aggregates markets – for an enterprise value of $220 million.

T

HE ACQUISITION will be funded from existing bank facilities and will be immediately earnings accretive with post-tax returns (before integration costs) expected to exceed Weir’s cost of capital in the first full year of ownership. Integration costs are expected to total $10 million over a twoyear period.

Weir is a global market leader in the provision of pumping equipment to the mining mill circuit, which separates rock from ore. The acquisition of Trio will build upon Weir’s recent successful entry into the adjacent comminution segment of the mill circuit. While leveraging off Trio’s cost-effective manufacturing platform, the acquisition enables Weir to provide a more complete product and service offering to existing mining customers.

A case in point The challenges faced, when trying to expand aggregate reserves in metropolitan markets, present herculean problems for alluvial aggregate producers. Often, the most expeditious pathway is to dig deeper into existing pits, which necessitates processing sand and aggregate that was

previously deemed too problematic for achieving necessary cleanliness and durability specifications.

Trio recently worked with a large, vertically integrated producer who invited them to help tackle such a challenge. Trio’s task was to provide an optimised solution that would utilise existing customer equipment while minimising additional capex investment in additional equipment. By developing a plan that reconfigured the existing equipment, Trio helped them add new equipment to process the more challenging material found deeper in their deposit.

The company’s application engineering group provided the complete process flow solution and collaborated closely with plant operations personnel. In the end, the plant reconfiguration required three Trio units combined with some specialty equipment from other suppliers to complete the upgrade.

As shown above, one of the key additions that enabled the plant to achieve clean specification material was the addition of a Trio twin 36" blade mill and modular support structure at the beginning of the process. The blade mill aggressively

Trio's crushing and separation equipment

mixes the aggregates and sand with a small amount of water to provide the necessary attrition scrubbing required in the first step of the process. Retention time within the blade mill can be adjusted with different paddle configurations in the machine and by adjusting the installation angle. The user-friendly access provided by the modular support structure helps facilitate the routine maintenance required to optimise the equipment performance and operating life.

The deleterious materials liberated from the dirty sands by the first attrition cell are removed from the process stream by the first Trio 44" fine material separator.

It also transports and prepares the sand for the second attrition cell. The sand processing is completed by the second Trio 44" fine material separator, which makes the final classification and dewaters the finished sand product in advance of stockpiling.

The equipment commissioning went well and culminated in an on-time, on-budget project that further solidified Trio’s relationship with this important customer.

IN SID E M IN IN G 1 1 /1 2 | 2014 41

STRATEGIC PARTNERS

TECHNOLOGY

60 YEARS

A piece of history

Advert15110114

F

Born and bred right here - Bell is Africa’s very own global equipment supplier. With support from our strategic partners we deliver a full range of premium machines. All built tough for our harsh environment.

All supported by 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.

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

ROM A DREAM to a global manufacturer, Irvine Bell built his company, and left a lasting legacy to his three sons. The memory of this creator of engineering excellence in local manufacturing will never be forgotten.

Bell Equipment celebrates its 60th anniversary this year, which provides an opportune time to look back at the early days of the company and how the values and innovative thinking of Irvine Bell gave rise to one of the country’s manufacturing icons that designs and produces worldclass equipment for the global market.

Irvine was born in 1920 and, as such, grew up in the Great Depression. He had an early – and enduring – fascination with tools and machines. Even during his school days, he could never stay out of workshops. Whatever nobody else would teach him he taught himself, whether it was servicing starter motors or refurbishing used batteries.

A fitter and turner by trade, Irvine returned home from serving five years in the Army Corps of Engineers during the Second World War and started a small general engineering and equipment repair shop on a farm in Empangeni in 1954 to serve the pioneer farming community of Zululand.

With his innovation and vision, the company provided sugar-cane farmers of that time with refreshing solutions to improve

42 I N SID E M IN IN G 1 1 /1 2 | 2 0 1 4

Bell Equipment founder Irvine Bell with his sons (from left) Pete, Paul and Gary PHOTO: THE MERCURY

efficiencies on their farms. A milestone in the company’s history came in 1964 when Irvine developed a tri-wheeled cane-loading machine, which revolutionised the sugar-farming industry and is still widely in use today. Irvine is credited with taking time to listen to his customers, thereby enabling him to understand their needs and provide solutions, and this ethos continues today throughout the company’s design, manufacturing, distribution and support network.

Today, Bell is a leading global manufacturer, distributor and exporter of a wide range of material handling machines, which are marketed and distributed, both locally and internationally, through a wide network of branches and independent dealers. The company supplies machinery to the sugar, forestry, mining and construction industries worldwide and has about 3 200 employees across the globe.

As one of the global leaders in the articulated dump truck market, Bell Equipment’s engineering expertise and product quality are comparable with other global players in the industry and Bell is immensely proud of the groundbreaking technological advancements it has developed on South African soil with its team of local engineers.

TECHNOLOGY

E

delivered on time with the necessary paXPLORATION FOR diamond deCIS in cooperation with Compax (Israel). A perwork to meet Russian conformity and posits in Russia’s Vladimir Grib central operators’ control room allows for permits for use. field started in the mid-1990s. plant control and management informaThe mill’s discharge is fed into three douToday it is among the largest tion systems. ble-spiral classifiers to wash the -1 mm mining and concentration complexes in A distributed network allows for localmaterial and then to the 60 tph Tenova the world. Developed by OAO Arkhanised control of all key process areas for Bateman DMS plants and 30 X-ray separagelskgeoldobycha, a subsidiary of OAO system integrity. tors manufactured by Russian ZAO NPP Lukoil, one of the long-established comThe success of the project resulted from Burevestnik. Density control systems enapanies in Russia’s European north, and early engagement in the contracting and ble automatic regulation by measuring the which specialises in exploration, mining implementation methodology. The promedium density using electromagnetic and minerals processing, marks the sucject cooperation between OAO Arkhandensity meters, allowing the average dencessful delivery of the project from congelskgeoldobycha (OAO Lukoil) and sity to be maintained close to the required cept to production.

Tenova Bateman CIS started as early as set point. For process control purposes, Tenova Bateman, a subsiduary of Tenova 2008, during the deposit preparation for the QC area is equipped with a standard 1 Mining and Minerals, secured the contract the industrial development and executph Tenova Bateman DMS modular plant. for the EPCM (engineering, procurement tion of the bulk-sampling campaign. This The plant is situated in a sensitive forand construction management) of the included beneficiation of ore samples at est area and utilises a closed-circuit water modular treatment plant. A critical factor a 5 tph Tenova Bateman modular plant, supply. The combined pumping station in meeting the requirements of the conwhich was designed for autonomous is equipped with slurry pumps for tailtract is the plant’s ability to perform in the operation without any connections to ings transfer to the tailings storage facilextreme weather conditions of Russia’s external utilities. ity. An automatic flocculant preparation sub-arctic environment.

Tenova Bateman modular plants have and dosing station feeds flocculants into The contract included the supply of a been supplied to Russia for over 15 years slurry pipelines. process equipment package for a 4.5 Mtpa and have proven especially efficient in The electrical and process control equipdiamond treatment plant, electrical equipremote areas with harsh climatic condiment was designed by Tenova Bateman ment and a state-of-the-art automatic tions, poor infrastructure, and limited monitoring and process conskilled manpower. trol system, as well as two With some 500 modular 60 tph and one 1 tph dense plants installed since the media separation (DMS) 1960s, Tenova Bateman modular plants. modular plants offer comEquipment was sourced petitive mineral processing worldwide from globally recogpackages for lower tonnised manufacturers of mining nages, while reducing risk equipment and process develby precommissioning beopers, with all equipment comfore-site erection. Tenova plying with Russian standards.

Bateman’s engineering and Particular attention was given EPCM skills and modular to the equipment delivery to solutions have been proven the remote site, since the exon some of the most exactisting roads have certain load ing mineral resource prosize and weight limitations.

Mining all year round in Russia’s far north, jects, in the most difficult Out-of-gauge equipment was of terrains. sub-arctic environment is particularly supplied as individual parts, with the weight of each piece Diamond processing plant challenging, especially in winter where not exceeding 37 tonnes. All in Russia's harsh Vladimir equipment was successfully Grib field temperatures drop down to -19˚C.

Extreme

environment EPCM

IN SID E M IN IN G 1 1 /1 2 | 2014 43

MINE SERVICES

Uniquely different Tharisa, a shallow and largescale open-pit PGM and chrome mine, which has an estimated open-pit life of more than 23 years and an estimated further 36 years underground, has been in production since November 2009. The question is: what and how did they do it?

The answer is quite simple. They outsourced their drilling, blasting, loading and hauling to a mining contractor. Since the start of November 2014, Na-Sera Mining Services, a 49.5% black-owned leader in the mining and quarrying environment has taken over the contract. This company believes in and delivers innovative solutions to problems and challenges, possesses solid operational experience backed by all the necessary qualifications, which they strongly regard as the means of providing a quality service, while always following a safety-first culture, and good, hard, honest work. These are the attributes that will be the key to Tharisa’s continued success.

Na-Sera believes that success is achieved through people. Every worker is treated with respect, and is expected to be trustworthy, honest, committed and hardworking. Given this, they continuously develop their people, from the bottom to the top. Everyone has a future, and everyone is trained to be multi-skilled. In Na-Sera’s books, reliability is the key word.

When you dig a little deeper you usually find the real story. In this case, it’s the reason why one mine remained operational while all the others around it had to shut down.

T

HE MOST AMAZING fact about the Tharisa platinum mine near Marikana in the North West is that it lost not one tonne of productivity during the entire five months of the platinum mine strike that rocked the South African economy during the first half of 2014.

ABOVE Loading ore for processing BELOW The Tharisa platinum mine near Rustenburg

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MINE SERVICES

At Tharisa’s Marikana mine, Na-Sera handles the mining side of all reef material and management of ROM (run-of-mine) while Tharisa handles the minerals processing side. Monthly volumes average 400 000 m3 drilled, blasted, loaded and hauled. In tonnes, this equates to 1.2 million per month. To maintain this production rate, eight DM30 II Atlas Copco rotary blasthole drill rigs, eight 777G off-highway Caterpillar tucks, 12 x 740B articulated Caterpillar trucks, three D9T 21 Caterpillar bulldozers, two D7R 15 Caterpillar bulldozers, two 986H Caterpillar wheel loaders, and a service fleet are in operation, providing a fleet of 41 for the loading and hauling. The logic behind using specific equipment brands, such as Atlas Copco, Caterpillar and Lieber, for excavators, is simply one of logistics, service excellence and productivity. Downtime is money lost. Preventative maintenance through a planned maintenance and replacement programme is a non-negotiable and critical operating success factor.

For the blasting side of the operations, Na-Sera uses Sasol Nitro, a division of the Sasol Group, who produces and markets commercial explosives, a wide range of specialised blasting accessories and diversified bulk explosives, which are used in mines and quarries, as well as supplying a range of additional services to Na-Sera.

Sasol Nitro, who developed the world-leading Expan low-density ammonium nitrate (LDAN) technology for more efficient, more cost-effective blasting operations, conforms to ISO 9001 quality standards. This means that Na-Sera, with its partnership with Sasol Nitro, can ensure the best fragmentation blasting practices and technical support services with its Sasol Nitro service team, including site managers and certified blasters, on-site.

Besides the Tharisa mine, Na-Sera is active on two other mines in providing a full mining service. Rustenburg Minerals Development Company’s Vogelstruisnek operation, a new contract, will see Na-Sera deliver an average of 10 000 tonnes of chrome, over a distance of 15 km, to the mine’s processing side on a monthly basis. At Harmony Gold’s Kalgold operation, Na-Sera will deliver an average of 800 000 tonnes of gold-bearing earth per month over a distance of 2 km.

In short, Na-Sera is positioning itself in the open-pit mining industry as a company that delivers a full mining service – drilling, blasting, loading and hauling. The company has the backup of a highly qualified and experienced technical team with the support of fully equipped workshops, on-site, as well as a main workshop in Rustenburg. The company is geared to ensure the availability of its fleet at all of its operations because of its proactive management approach, and because the company places safety first, as its number one priority, it is fatality free.

FROM TOP RIGHT (From left) Hennie van Zyl, Johan van der Merwe (COO) and Anton Treurnicht Atlas Copco's DM30 II rotary blasthole drill rig 986H Caterpillar wheel loaders 740B articulated Caterpillar trucks

Na-Sera delivers a full mining service: drilling, blasting, loading and hauling

+27 (0)12 001 5046 info@nasera.co.za www.nasera.co.za

IN SID E M IN IN G 1 1 /1 2 | 2014 45

MATERIALS HANDLING

Major empowerment deal

T

HE INVENTOR of the ‘transfer chute system’, Werner Baller of WEBA, has concluded a major empowerment deal with Hlanganani Capital that will boost its involvement with the mining industry in Africa.

WEBA Chute Systems has successfully concluded a major empowerment deal with Hlanganani Capital that will see the company that pioneered the transfer chute system for bulk materials handling in the mining industry gain further traction in

Africa and other emerging markets such as South America. In addition to the empowerment deal, the company has announced an overhaul of its executive management structure that will see the eventual retirement of founder and inventor Werner Baller. Farouk Abrahams from Hlanganani Capital becomes a director of WEBA in order to boost the existing roles of Mark Baller as managing director and Alwin Nienaber as operations director.

“We wanted a partner that could bring value to the company. We shopped long and hard until we found this group,” Baller says. Hlanganani Capital is a black-controlled private investment and advisory entity primarily focusing on arranging, participating in and managing FROM FAR LEFT Mark Baller, Werner Baller and Farouk Abrahams

private equity investments mainly in the mining, engineering and related service sectors. It focuses on delivering significant shareholder value through sound strategic investment practice while contributing to the transformation of the economy and society at large.

Hlanganani Capital was established by Rowan Smith, Farouk Abrahams, Anton Millar and Olivier Barbeau with a strategy to invest on a partnership basis in a diversified portfolio that takes advantage of the growth prospects offered in sub-Saharan Africa.

The empowerment deal followed the decision by Werner Baller, the original majority shareholder of WEBA, to transform the company into a fully compliant BBBEE entity that also fulfils the obligations of the Mining Charter.

“The plan is to take the company that my father nurtured over the years to the next level.”

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Coralynne & Associates +27 (011) 849 3142

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MATERIALS HANDLING

Innovation from within

F

OR SOME YEARS now, Hansen Industrial Transmissions (HIT) has been very successful in supplying single-stage blower drives.

Having had no dedicated single-stage solution for the larger sizes, a special solution was designed starting from the standard horizontal, parallel, two-stage Hansen P4 housing (size G, H, J or K – with one gear set). What started as a one-off project has turned into recurring business.

HIT sees significant market potential for similar single-stage drives, also outside Europe, mainly in the mining sector (e.g. for centrifugal slurry pumps) and for applications such as blowers, compressors and refiners, as well as equipment for the chemical industry and the energy sector.

These applications however would not benefit from a specific large single-stage housing i.e. those used for the P4 single-stage units with a dedicated housing.

HIT therefore reused its current robust P4 two-stage housing.

Using its in-house resources, HIT generated a large number of possible gear sets.

From a mechanically optimised subset, a final selection was made looking at dynamic and noise properties, which led to a highly optimised gear set range. With a selection ratio up to 1% exact in almost any case, the optimal working speed is matched as near as possible.

The specially designed lubrication for this new product range – based on the multi-megawatt principle – ensures the gear set and all bearings are pressure lubricated. A new type of sprinkler caters for optimal oil distribution

over the gear teeth. Due to the high installed powers, a cooling group is indispensable. Taking into account the high peripheral speeds at the shaft ends, HIT provides its Hansen Oil-lock sealing at all shaft ends and fabricates the oil drains large enough so no pressure is built up and leakage is prevented.

Hansen's P4 range of singlestage gear units also comes in a parallel horizontal configuration

IN SID E M IN IN G 1 1 /1 2 | 2014 47

MATERIALS HANDLING

Lower emissions and fuel consumption The Volvo L110H and L120H wheel loaders, which feature a powerful Tier 4 Final/Stage IV-certified engine, meet strict emissions legislation, while improving fuel efficiency by up to 18%.

N

EW VOLVO L110H and L120H wheel loaders are among the company’s most environmental and fuel-efficient machines to date. The company’s latest generation of machines for the 18 tonne to 22 tonne class, they are powered by an 8 ℓ Tier 4 Final/Stage IV-certified engine with fully automatic regeneration that combines high performance with low emissions and low fuel consumption.

The inherent fuel efficiency of the Volvo D8J engine is enhanced by the wellmatched Volvo power train and intelligent hydraulics, which only supply power on demand. The load-sensing hydraulics also ensure fast response for outstanding control over the load, as well as shorter cycle times. Another intelligent feature, the Reverse-By-Braking (RBB) function, automatically reduces the engine rpm and applies the service brakes when the operator changes the direction of the machine.

This not only conserves fuel but also reduces stress on the drive train, thereby extending component life. Meanwhile, Volvo OptiShift technology combines the RBB function with a lock-up torque converter to create a direct drive between the engine and transmission, eliminating power losses in the torque convertor and reducing fuel consumption by up to

48 INS I DE MI NI NG 1 1 / 1 2 | 2 0 1 4

18%. The eco-pedal further reduces fuel consumption, thanks to mechanical pushback force, which encourages the operator to ease off the throttle when the engine rpm is about to exceed the optimum operating range.

One machine, many capabilities Not only are the L110H and L120H wheel loaders highly efficient, they are also highly versatile and can be used for a wide range of applications – from material handling and rehandling, and road construction to utility work.

These 18 tonne to 22 tonne machines are fitted with a choice of unique Volvo attachments – including a variety of buckets, material handling arms, forks, sweepers and snow blades – to achieve maximum uptime and profitability from each machine. The attachments are designed as an integral part of the wheel loader, with functions and properties ideally matched to minimise energy losses and increase productivity. Meanwhile, the unique Volvo Torque Parallel (TP) linkage delivers high breakout torque and excellent parallel movement throughout the entire lifting range and the optional boom suspension system reduces bucket spillage, boosting productivity by as much as 20% on rough ground.

Feels like home The productivity of each work shift is also boosted by the wheel loaders’ industry-leading cab, which provides a safe, clean and comfortable operator environment, whatever the conditions outside.

The operator enters the ROPS/FOPS-certified cab safely and easily via a three-point access ladder with anti-slip steps, supported by sturdy and ideally positioned handrails. The wide doorframe opens at a convenient 95 degree angle and can even be opened remotely as an option. A cab entrance light is also available as an option for increased safety when entering and exiting the machine.

Inside, the cab is spacious, with plenty of storage for personal belongings. Internal noise levels are kept to a minimum, thanks to sound insulation, while improved seat and vibration protection ensure a smooth and comfortable ride. Air quality is guaranteed by an industry-leading filter that allows 90% of the cab air to be recirculated for continuous dust removal.

To limit operator fatigue, all the controls and information panels have been ergonomically positioned. For ease of operation, the optional multifunction joystick gives the operator simultaneous and precise control of the hydraulic functions.

Forward, reverse and kick-down functions are also included on the right-hand arm rest. The machine’s vital information – such as fuel and oil levels – is displayed on an easy-to-read screen that is clearly visible from the operator seat, even in bright sunlight. Basic configurations and tests can be performed without the operator having to move from the seat.

Daily service checks on the machine can be carried out quickly and simply with grouped service points. The engine hood opens electronically so the operator or technician can easily gain full access to the engine compartment. This helps the machine to get back on the job as quickly as possible. The rear-axle cradles contain maintenance-free, lubricated-for-life bushings and bearings. As for the cooling fan, it can be reversed for self-cleaning of the cooling units.

This translates into reduced total costs of ownership and increased profitability throughout the life of the machine.

PIPES, PUMPS & VALVES

Getting out of

deep water

I

Too much of a good thing can be a bad thing, especially rain. It can play havoc with mining. This is particularly

N 2008, heavy, continuous rains wreaked havoc with coal supplies to Estrue kom that in turn affected its ability to supply electricity.

Rolling blackouts – as breakdowns, maintenance work and excessive rains put about a fifth of Eskom’s capacity out of service – were the order of the day.

The economic impact was substantial.

Wet coal, which burns less easily and blocks delivery chutes, put a serious damper on Eskom’s ability to supply South Africa’s electricity. Given that Eskom supplies approximately 95% of South Africa’s electricity, this is a huge problem. Perhaps less significant, but no less problematic, is the rainwater accumulation at the deepest points of openpit mines.

SRK, consultants to the mining industry, believe the management of water on a mining project will become ever more important in the future. If 2008 is anything to go by, and within the context of climate change, this is an important issue. A partially flooded open-pit mine is TOP Open-pit mines always accumulate rain water at the bottom of the pit BELOW A Gorman-Rupp Prime Aire trailermounted centrifugal

of open-pit mines. BY TONY STONE typically the result of the poor implementation of stormwater controls that lead to major expenses in rehabilitation, as well as significant losses in production, which could be avoided with due care.

One means of achieving this is to lower the water table outside the open-pit mining area in order to prevent any ground water from seeping into it. If any seepage or heavy rain occurs, this water can be pumped out from the bottom of the pit using high-head drainage pumps. If the solids content in this water is high, the use of submersible slurry pumps for the drainage operation.

For site dewatering and remediation, a pump is required, depending on the extent and depth of the problem, with intake sizes between 7.5 mm to 30 mm, heads up to 140 m, flows up to 24 000 litres per minute and 8 mm solids handling capability. The pump will need to be hard-working, dependable and able to tackle everything, including clear liquids, tough solids, and slurry applications.

Quite simply, you will need to move large volumes of water rapidly, even when sticks, stones, and other debris would normally present a problem.

Groundwater flow in open-pit mines Groundwater flow in the vicinity of open-pit and underground mines varies three-dimensionally and with time. Assessing mine dewatering commonly requires the development of 3D numerical groundwater models, based on 3D geological, structural, and hydrogeological data, to fully characterise the groundwater flow.

SRK often applies the finite-difference code Visual MODFLOW-SURFACT in mine dewatering projects. This code goes beyond the standard MODFLOW code to simulate saturated/unsaturated conditions (multiple water tables), open-pit excavation (using seepage face cells and collapsing model grid), and dewatering wells using the fractured well package.

The hydrogeological team at SRK uses numerical modelling as an integral tool for the wide variety of mine dewatering projects. All of these models are used to simulate passive inflow to open-pit mines.

GROUNDWATER FLOW IN OPEN-PIT MINES Groundwater flow in the vicinity of open-pit and underground mines varies three-dimensionally and with time.

Assessing mine dewatering commonly requires the development of 3D numerical groundwater models, based on 3D geological, structural, and hydrogeological data, to fully characterise the groundwater flow. SRK often applies the finite-difference code Visual MODFLOW-SURFACT in mine dewatering projects. This code goes beyond the standard MODFLOW code to simulate saturated/unsaturated conditions (multiple water tables), open-pit excavation (using seepage face cells and collapsing model grid), and dewatering wells using the fractured well package. The hydrogeological team at SRK uses numerical modelling as an integral tool for the wide variety of mine dewatering projects. All of these models are used to simulate passive inflow to open-pit mines.

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PIPES, PUMPS & VALVES

Piping caustic liquids

BY JOOST DE VREE

T

HE EXACT FUNCTION of a pipe or tank and its operating conditions, including very aggressive or corrosive environments, are the main considerations in material selection.

Glass-fibre-reinforced plastic (GRP) is a combination of two or more materials (reinforcing agents and matrix), differing in form or composition on a macro scale. In (glass) fibre-reinforced composites, fibres are intended to carry the load, while the surrounding resin matrix sets the fibres in the required orientation. When the materials are compatible, the matrix also acts as a load-transfer medium between the fibres, and protects them from environmental damages due to temperature changes, humidity and corrosion. The term GRP implies glass reinforcement and not any other fibre such as aramid, carbon or polyester (FRP).

There are hundreds of plastic types Pakistan's Feisalamade & Keteli electrical plant and Qinshan nuclear power station

IN SID E M IN IN G 1 1 /1 2 | 2014 51

GORMAN-RUPP engine-driven trash pumps are the perfect solution for sewage bypass operations, construction site dewatering, hydraulic fracturing and all your other tough pumping applications.

Gorman-Ruppâ&#x20AC;&#x2122;s priming-assisted pumps feature a positive priming and sealing system that virtually eliminates leaks, reducing environmental concerns and allows these pumps to run-dry indefinitely.

For positive, reliable priming time after time, you can count on Gorman-Rupp pumps.

GORMAN-RUPP AFRICA 2 Kelly Road, Jet Park, Boksburg Q Gauteng, South Africa PH: +27 11 397 3536 Q WEB: www.pumptron.co.za Q EMAIL: info@pumpton.co.za 513-GRA

ŠCopyright, The Gorman-Rupp Company, 2014

AFRICA

WE ARE THE PEOPLE BEHIND THE PLASTIC PIPING SOLUTIONS WHICH MANAGE WATER, WORLDWIDE WE ARE THE IDEAS FOR MOVING, STORING AND RE-USING WATER FOR MINING FACILITIES AND INFRASTRUCTURE ACROSS AFRICA

British Manufacturer

We are a global supplier of plastic piping systems for industrial as well as infrastructure, residential and commercial applications.

We are a total solutions provider with an impressive portfolio of successful projects including the Marampa and Tonkolili mines in Sierra Leone.

We are a UK manufacturer, bringing a guarantee of quality, reliability and technical expertise. We offer expert project support, and are able to meet the most challenging supply demands, helping customers manage water effectively on time and on cost. We are a thought and practice leader, with a track record of innovation. We are experts. We are Polypipe.

Find out how we can help you. Visit our website: www.polypipe.com/mining or email: international@polypipe.com.

www.polypipe.com/mining

PIPES, PUMPS & VALVES

Glass-fibre-reinforced plastics (GRP) are being used as an alternative to steel, stainless steel and rubber-lined steel

available (such as thermoplastics, thermosets, and elastomers), and also many variants of glass reinforcement (such as chopped strand mat, woven rovings and combination mats) – which also differ between manufacturers. Therefore, GRP is a description representing an extensive family of composites with an extremely variable range of properties. The type of GRP usually specified for tanks and pipes is a composite of glass fibres with more chemically resistant resin types like vinylester, isophthalic polyester or epoxy.

Composite pipes and tanks Pipe systems and storage tanks are constructed from a wide variety of materials such as metals (carbon steel, stainless, alloys), plastics (thermoplastics, thermosets, elastomers), inorganic materials (concrete, ceramics) and wood. The ageing behaviour of GRP material depends on different circumstances (time, temperature, media, pressure, etc.). The rate of success (lifetime) is relative to the composition of the GRP component.

Corrosive and erosive attack determines the service life. The exact function of the pipe or tank and its operating conditions are the main considerations in material selection. Cost is also an important factor.

But whole-life cost analysis should be used, which not only compares material costs, but should also compare transportation, installation, maintenance and operational costs during the service life of the pipeline or tank. The environmental impact of a failing pipe or tank also has to be taken into account. In many cases, GRP pipes and tanks will offer a strong, reliable and cost-effective alternative.

The many advantages of composites may be summarised as follows: • superior strength- and stiffness-to-weight ratios. For the same strength, composites can be 80% lighter than steel and 60% lighter than aluminium • ability to withstand high, continuous GRP IN SOUTH AFRICA Industrial water cooling and GRP experts, Industrial Water Cooling (IWC), based b d in i Isando, I an Isa Gauteng, have acquired acq qui the Vectus pipe system sysste from Fibrepipe Fibrepipe South Africa.

Rogerr Rusch R (left), MD at IWC, IIW says, “The acquisition acq of the the Vectus V pipe system s is a solid addition to

GRP products are often used in very aggressive or corrosive environments. Such applications include: • fire water systems (fire water (oxygen) can cause corrosion, especially in partially dry systems). Also, the below-ground environment can be highly aggressive • chemical process lines • cooling water lines (see fire water systems)

• demiwater (demineralised water is a highly aggressive medium often causing corrosion) • industrial effluent systems • high-pressure pipelines (often containing aggressive media such as a combination of saltwater and oil, or brine). The smooth inner surface of GRP also results in lower friction and higher flow efficiency • jacket pipes (corrosive soil, non-conductive in railway areas where stray current is a problem) • exhaust lines and chimneys (corrosive medium, lightweight) • handling and storage of almost all aggressive chemicals.

GRP composites have found a wide range of applications in industrial environments over the last four decades. Most progress has been made in the areas of composite pipe work, storage tanks and fluid handling equipment. The high cost of replacing steel (alloys) and the increased service life in new constructions favour the use of composites that withstand extreme conditions.

GRP leads to lower life-cycle costs, reduced problems with corrosion and a reduction in structural support sizes, and material handling problems during construction. The resistance of GRP to corrosion helps to improve reliability and safety. GRP pipes can be used for fire water systems, seawater cooling, draining systems, (chemical) process lines, fuel lines, sewerage systems and much more.

The cost advantages of GRP plant are increased even more when they substitute expensive corrosion-resistant alloys such as copper-nickel alloys, duplex/super duplex stainless steel, and titanium.

The selection of suitable resin plays an important role for imparting durability of the composites when exposed to aqueous fluids or gases.

our existing GRP manufacturing plant affording full turnkey GRP solutions across industries in South Africa and Africa.”

The GRP pipe system production method is a discontinuous double-helix reciprocalfilament winding process that gives the pipes a balanced combination of axial and hoop mechanical properties. The system also includes a complete range of standardised and special fittings.

IWC’s existing GRP design and manufacturing capabilities extend to freestanding GRP cells and GRP liners

for electrolytic and electro-winning metal refineries; GRP scrubbers, cooling towers, process vessels and GRP storage tanks, plus the design, manufacture and installation of GRP piping and fittings from 25 mm up to 2.5 m in diameter, GRP ducting, GRP overwrapped thermoplastics and fluoroplastics such as polypropylene, HDPE, PVC, PVDF, PFA, ECTFE, pipelines, fittings, tanks, process vessels, ducting, stacks, etc., and polypropylene, PVC and HDPE vessels and piping.

operating temperatures compared to thermoplastics: up to 110°C in many composites; even exceeding 200°C in special cases • highly corrosion-resistant in almost every chemical environment • electrically insulating in general (depending on reinforcement selected) • when required, composites can be made electrically conductive or selectively conductive • low thermal conductivity in general, but can be made conductive when required • exceptional freedom of design; composites can be formed into many complex shapes • outstanding durability; well-designed composites are expected to have an almost infinite lifetime, even in extremely harsh environments • corrosion resistance: the non-reactive nature of many resins and reinforcements can be custom-selected to resist degradation by many common materials and in corrosive environments • lower maintenance and replacement costs.

Applications

IN SID E M IN IN G 1 1 /1 2 | 2014 53

PIPES, PUMPS & VALVES

Creative alternative Mines are often established where municipal infrastructure does not exist, such as a waterborne sewerage system. So, ‘what to do’ is the question?

Fortunately there are creative alternatives.

G

OWRIE FARM is a residential and golf estate in Nottingham Road situated in the KZN Midlands. The original farm property did not have a waterborne sewerage system, therefore installation of a septic tank type of soak-away system was necessary. Consultant Drennan, Maud & Partners was appointed to carry out a feasibility study of the on-site wastewater disposal and make suitable recommendations.

Solution The proposal suggested that a percolation test be carried out for each of the three houses on the property. Typically, a four-bedroom house on this estate produced effluent of 1 100 litres and needed an effective evaporation area of 470 m2. The outflow from the septic tank was to be discharged into a conventional soak-away system with a minimum length of 31 metres.

On-site conditions, including a clay content in the soil, restricted the depth of excavation for installation of the drains where deeper excavations may have resulted in DIAGRAM 1 (Below left) The Infiltrator

Chamber System. Highly effective, easy to install

54 INS I DE MI NI NG 1 1 / 1 2 | 2 0 1 4

the drains being placed on less permeable or bedrock material. Kaytech provided an alternative solution to the traditional stone-filled drains using the Infiltrator Chamber System. The Infiltrator chambers provided a maximum exposed infiltrative area and since they only require an excavated depth of 700 mm to be installed, they made for the most viable option.

The Infiltrator Chamber is a pre-manufactured open underground unit that acts as a direct replacement for conventional stormwater and wastewater attenuation, promoting effluent infiltration into the soil efficiency. The lightweight units and endcaps were supplied separately to maximise transport, handling and storage of the units. The Infiltrator Chamber System is a direct replacement for old-fashioned stone and pipe French drain soak-away and may require as little as half the space, offering designers, installers and homeowners greater flexibility in placement of this French drain soak-away alternative, while minimising disruption of the landscape and saving money. The quick installation minimised heavy construction traffic that may damage and compact sensitive soils.

Quick and easy to install, Kaytech’s Infiltrator Chambers have the advantage of

being 100% environmentally friendly as they are produced from recycled plastic waste material. They are also chemical-resistant and UV stable, with a powerful arch design that supports axle loads of 70 kN, with 300 mm of compacted cover, equivalent to an AASHTO H-10 load rating.

A total of 200 Infiltrator Chambers were manually installed to accommodate the effluent from the three properties on the estate.

Benefits Compared to a conventional stone and pipe French drain system, this method halves the installation time and results in a 43% cost-saving of approximately R7 500. On returning to the site after nine months, Kaytech’s system is working effectively. The benefits of Infiltrator Chambers compared with stone and pipe systems are: • small footprint with equal or better performance allowing less site disruption • larger effective infiltrative area per linear metre allows installation on limited area sites • fast, easy installation saves time and money • equivalent or greater storage capacity means increased safety factor and peace of mind • higher long-term acceptance rate guarantees a reliable, top-performing system • patented sidewalls provide maximum infiltration • entire bottom of chamber is open for unobstructed infiltration into soil.

Kaytech’s superior technology includes: easy to handle lengths, which allow for more installation flexibility; system sizing determined by local shaping capabilities; advanced contouring capability with Contour Swivel Connection; StraightLock Tabs ensure straight alignment, compact nestling provides more trench length in a smaller storage area; and MultiPort End Caps offer multiple piping options and minimise the use of pipe fittings.

University laboratory research and extended field evaluation has verified the infiltrative efficiency of the open-surface architecture provided by Infiltrator Chamber Systems over old-fashioned stone and pipe systems.

PIPES, PUMPS & VALVES

Value-driven water management solutions

BY JONATHAN MEINTJES

R

ESPONSIBLE STEWARDSHIP of this vital resource is a must, but how do we determine optimal solutions that will benefit both the business and the community?

Creative and practical solutions for sustainable water management are essential for good mining practice. Not only do mines need to use water in significant quantities, but the water that comes into contact with mining activities also can have contact with communities around the facility and far downstream.

Current debates on the potential of climate change due to our excessive use of fossil fuels over the past 150 years has highlighted the potential crisis that many communities may experience through issues pertaining to water. In some regions of the world, the incidence of violent storms and floods presents a particularly dramatic scenario, while the prospects for Africa

are much the opposite, with the potential for harsh and protracted droughts. In any event, water, or the lack of it, is going to be a strong focus in the years to come.

Mining, by virtue of its nature, needs water and also can be a potential contaminant of this precious commodity. Communities downstream of mines are vulnerable, where water flowing from mine properties is used for drinking and washing. Where water is tainted with traces of poisons like arsenic and cadmium, the consequences of usage can be disastrous.

Given the fact that many, if not most, mines in Africa are in water-scarce places, the potential for recycling of this commodity becomes a priority. The problem is, how effectively and what is the appropriate treatment necessary to ensure that it is safely reusable? What works in one place may not necessarily work in another and for that reason unique solutions need to be

developed. It is therefore disingenuous to attempt to foist a one-size-fits-all solution on any given operation.

Notwithstanding, there is a fine balance between responsible care and cost. Unique solutions sometimes are prohibitively expensive and the temptation is to overlay the problem with a generic solution that costs less. The problem with this is that results may be less than satisfactory and, in the long run, may end up costing more.

A useful mechanism for designing and developing systems is a workshop process known as value engineering. This process has been used to identify and develop optimal solutions to a range of operational problems and opportunities. The process used evolved in response to the manufacturing requirements of General Electric during the Second World War. Value engineering is a function-based approach to problem solving which ensures that optimal value is achieved.

Typically, a value-engineering approach would draw on the intellectual resources of a wide range of people who have an impact on the problem or opportunity being addressed. This ensures that ownership for the solutions is achieved across the organisation and not just with one department perceived as having the vested interest in it. The process is consensus-driven, which also means that the results are fully owned by everyone.

Mines that need to address their water issues – be they around the interaction with the operation and the surrounding communities, or in the process of recycling the resource for internal use – would do well to develop value-driven solutions using proven techniques such as value engineering.

Ultimately, a carefully thought-through, consensus-driven method will yield benefits that will be far better than a generic one-size-fits-all approach.

IN SID E M IN IN G 1 1 /1 2 | 2014 55

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THIS & THAT

In remembrance...

A brave artist and sculptor – himself a victim of a shooting – has come forward with a vision to create a lasting symbol, a memorial of remembrance to the Marikana miners who died.

I

T WAS A CHANCE meeting. Tony Stone, editor of Inside Mining, and George Togara-Mudzvovera, artist, sculptor and curator of the Daville Baillie Gallery, got talking when Tony visited the Gallery to view the Kim Ludbrook ‘Mandela 2.8’ exhibition.

George, a permanent resident in South Africa who hails from Zimbabwe, was shot twice in the stomach and once in his right hand while on his way home in Mondeor south of Johannesburg.

Followed from a bank in Johannesburg to Mondeor, the criminal opened fire when George put up a struggle for his briefcase. After two months in

the Chris Hani Baragwanath Hospital and some months recuperating, George has nothing but praise for the hospital staff.

Now, this single father of a boy – because of his own experience – wants to honour the Marikana dead and wounded. Tony, who subsequently visited Marikana after that fateful day, was moved by the three small white crosses that bedeck the nottoo-big mound of rock upon which the

miners stood. For miles around this there is nothing but flat ground. In a way, the mound of rock stands defiantly, like the miners themselves, refusing to budge. But such stubbornness can be dissolved by a mightier power, as happened to the miners.

The Farlam Commission found that the police were clearly untrained and disorganised, unable to manage a protest situation and, when that small group of miners approached them, all discipline, of whatever they had, faded. Panic and individual self-preservation set in. When the smoke cleared, 34 men were dead, including the green-blanketed man.

The tragedy of Marikana was that the lives of fathers, sons and brothers were lost because leadership failed, the miners were misled and communications broke down. But, the time has come to heal. In the process, we need to learn and put past mistakes behind us. We need to build our future, together. At the same time, we need to remember the dead.

This is where the idea of a memorial comes in – one that reflects the bravery of all who died, the struggle for a better life, the travesty of the entire incident while at the same time embracing the principles Madiba left us in his legacy: that to heal we must forgive and reconcile.

It is planned that the unveiling of the memorial sculpture will be attended by the people, family members and loved ones, the Minister of Minerals and Energy and mining executives to commemorate the second anniversary of the Marikana massacre.

A sponsor is needed for the creation of the sculpture, its transport and installation. Anyone who is interested can contact Tony Stone via email at tony@3smedia.co.za.

INDEX TO ADVERTISERS Atlas Copco

36

Innovation Alliance

Babcock

49

Kaytech

Bell Equipment

42

Mining Indaba

Booyco Electronics

35

Mintek

Golder Associates

19

M&J Engineering

46

Hansen Industrial Gearboxes

47

Na-Sera

44

56 INS I DE MI NI NG 1 1 / 1 2 | 2 0 1 4

55

NuWater

OFC

IBC

Polypipe

52

Pumptron

51

Southern Mapping

31

Tega Industries

38

Trysome

IFC

Weir Minerals

40

2 OBC

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