MBA - July/August 2024 Magazine

Branches across Sub-Saharan Africa and value-added partners across Africa

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CONTENTS

July - August 2024

03

Editor’s Note Electrifying Experiences at Electra Mining

T

20

his edition is dedicated to the second Electra Mining Exhibition after the COVID pandemic.

It carries more significance, as the mining sector has all but recovered, with a number of mineral commodities in high demand. This is especially related to the minerals that are deemed critical to the green energy transition—critical minerals, as they are now called in mining parlance.

Talking about which, there are several ongoing projects in African countries to meet demand in the global electric vehicle sector and renewables. There is high demand for various technologies central to this.

Cover Image: Specialised Exhibitions

COVER STORY: PG 3

Electra Mining Africa

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2024: In 2022, Electra Mining Africa returned with a bang after a hiatus at the height of the COVID-19 pandemic to rave reviews. The 2024 bi-annual event promises to be bigger and even better by introducing more value-added services. The Specialised Exhibitions Team fields questions from Mining Business Africa.

This development bodes well for Original Equipment Manufacturers (OEMs), who have reciprocated by unveiling factory-fresh, pristine machines for various applications from pit to port. Some of the equipment incorporates artificial intelligence for better efficiency, safety, and energy efficiency.

We are looking forward to these and many more technologies from different organisations involved in the mining supply chain.

Electra Mining doesn’t disappoint. The event always exceeds the hype.

42

We are eager for an electrifying experience at 2024 Electra Mining!

Nick Barnes editor@miningbusinessafrica.com

TEAM Editor Nick Barnes editor@miningbusinessafrica.co.za +27 10 055 3356 Web/Sub-Editors Jimmy Swira Jimmy@miningbusinessafrica.co.za +27 10 055 3356 Anita Anyango anyangoanita18@gmail.com Contributing Writers Chantelle C. chantellec@miningbusinessafrica.co.za +27 10 055 3356

Susan M. susanm@miningbusinessafrica.co.za Sales and Marketing Winnie Sentabire winnie@miningbusinessafrica.co.za +27 83 530 6832 | +27 10 055 3356 Angeline Ntobeng angien@miningbusinessafrica.co.za +27 78 322 5938 |+27 10 055 3356

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In 2022, Electra Mining Africa returned with a bang after a hiatus at the height of the COVID-19 pandemic to rave reviews. The 2024 bi-annual event promises to be bigger and even better by introducing more value-added services. The Specialised Exhibitions Team fields questions from Mining Business Africa.

BA: What were the milestones of 2022 M Electra Mining?

SE: The biggest milestone has to be Electra

Mining Africa celebrating 50 years at the 2022 show; the inaugural show took place in 1972. It was also a 50 years celebration for those companies who had been exhibiting at Electra Mining Africa since the first show, underlining the success they had achieved at the shows over the years.

The industry gave its full support to Electra Mining Africa 2022, which had just short of 30,000 visitors through the gates and 650 exhibitors showcasing their latest products, innovations, and technologies.

We’re expecting to exceed those numbers this year.

The 2022 show was held after coming out of a very tough period following the pandemic.

The sense of anticipation and positivity that was expressed on the floor of the exhibition throughout the show were enormous. It was back to meeting face-to-face, making connections, and people loving the exhibition environment that had been missed.

Another milestone was the excellent innovation seen in the ‘New Products and Innovation Awards’, which is an Electra Mining Africa and South African Capital Equipment Export Council (SACEEC) initiative. A first for 2022 was the new forklift driver competition, organised in conjunction with Lifting Africa and the Lifting Equipment Engineering Association of SA (LEEASA), which saw many forklift operators competing for the coveted title of Forklift Driver Champion. The automation technology hall was a big addition to the show and very popular with visitors. The theme days, conferences, workshops and free-to-attend seminars were also well received.

There could be no better endorsement of the show than the almost 50% of exhibitors

of exhibitors who had already rebooked their stands for the 2024 show, even before the gates had closed on the 2022 show.

MBA: What is the relevance of Electra Mining in the context of lingering supply chain challenges impacting construction and mining companies in the region? SE: Exhibitions, and specifically we reference Electra Mining Africa here, are still extremely relevant and beneficial. Every two years at one venue for the five days of the show, industry comes together to trade and do business. Local and international exhibitors are looking to promote and sell their latest products, technologies, services and solutions. Visitors are looking to buy or learn about the latest products, technologies, services and solutions. Electra Mining Africa helps to stimulate trade in the industrial, manufacturing, and mining sectors of the South African economy. Any lingering supply chain challenges are not affecting this business exchange at the exhibition.

Regarding delays at the South African ports, this can pose a challenge to bringing in some of the equipment and machinery exhibited at the show. At a recent show of ours, there were some delays at the ports, and some of the machinery came in late. This did make show build-up a bit tricky as there were a high number of large and heavy machines being exhibited. Fortunately, everybody involved was incredibly professional, and everything was ready when the doors opened.

MBA: The conference and exhibition sectors have seen the introduction of niche technology. What innovations is Specialised Exhibitions introducing in 2024 to cope with this competition and, most importantly, ensure Electra Mining is still relevant and ahead of the curve? SE: Since the inaugural show in 1972, Electra Mining Africa has continually evolved over the years to ensure its relevance and to attract the right audience to the show. For example, there was not much talk of automation at the 1972 show, but in 2022 Electra Mining Africa introduced a dedicated automation hall highlighting the latest innovations and technologies. This year, the automation hall is even bigger, with an even greater focus on all that automation can offer.

2 Mining Business Africa | July- August 2024

Electra Mining Africa offers a 5-in-1 trade expo experience embracing the areas of mining, electrical, automation, manufacturing, power, and transport—all interconnected industries. It is a trade show that moves with the times; a show that helps build connections for future business growth.

As a trade show organiser, we understand the importance of markets and connecting buyers and sellers. We work hard to ensure we have a clear understanding of the industries that Electra Mining Africa represents to enable us to provide exhibitors with the right visitors. We work closely with our exhibitors and other industry stakeholders. Quality visitors who make purchasing decisions or strongly influence purchasing decisions are more important to exhibitors than the quantity of vsitors only.

The quality of the exhibitors is also important as people are giving up their time to visit the show and want to know that it is time well spent.

As follow-up to our shows we ask exhibitors and visitors to participate in post-show surveys to provide us with feedback as to whether we met their expectations. By staying closely in touch with the needs of all industry stakeholders, Electra Mining Africa does stay relevant and ahead of the curve.

This year’s Electra Mining Africa will be one of our best and biggest shows in the 52 years since the first show. We are already 30% bigger exhibitor-wise than we were in 2022.

As an organisation and a division of Montgomery Group, we have embraced the latest technology to best facilitate our business, from our marketing to operations and sales.

MBA: What about new value-added services and experiences for exhibitors and patrons?

SE: We are excited this year to introduce our new Platinum Guest visitor option. For a reasonable cost, visitors to the show can elevate their visitor experience by selecting the paid-for Platinum Guest option and benefiting from exclusive convenient parking, an exclusive registration area, and the welcoming air-conditioned lounge with complimentary refreshments, workstation facilities, and wi-fi availability, amongst other benefits. There is a limit of 100 Platinum Guests per day.

Electra Mining 2024 We’re really pleased that there will be an Inward Buying Mission attending the show this year, organised in partnership with the South African Capital Equipment Export Council (SACEEC). Electra Mining Africa is assisting delegates from neighbouring African countries and from Europe and South America to attend the show by subsidising some of their travel costs.

We are also thrilled that WiMBIZ is participating at the show this year for the first time. Representing 500 female-owned companies in the mining industry, WiMBIZ will create a networking space where visitors and exhibitors can engage and talk about beneficial business partnering opportunities.

There will also be a hosted networking function to facilitate these conversations.

The Southern African Institute of Mining and Metallurgy (SAIMM) and the Lifting Equipment Engineering Association of SA (LEEASA) will both be hosting conferences alongside Electra Mining Africa. Women in Mining South Africa (WiMSA) will conduct a half-day workshop. Visitors can increase their industry knowledge by attending the South African Institution of Mechanical Engineering (SAIMechE) free-to-attend seminars in Hall 9.

Across the five show days, industry experts will be sharing their knowledge and experience across many essential and current industry topics. The topics will align with our theme days: Sustainability Day, Women’s Day/Skills Day, Safety & Lifting Day, Innovation Day and South African Day. Organised in partnership with the South African Capital Equipment Export Council (SACEEC), we’re going bigger and better with the New Products and Innovation Awards competition this year. The awards recognise the outstanding levels of innovation at the show. More exhibitors will enter the competition this year compared to the 2022 show. The Forklift Driver competition, organised in conjunction with Lifting Africa and LEEASA, is also back this year on a much bigger scale with more entrants. The judges will be looking for exceptional forklift driver skills and the Forklift operators competing in the competition are looking to win the coveted title of Forklift Driver Champion.

Visitors will have the opportunity to connect with over 850 exhibitors across the six halls and extensive outside exhibit areas. The five days of the show will see thousands of people connecting across industries enjoying the face-to-face interactions, and thousands of new products and innovations will be seen on display. Our five shows concept provides an exciting showcase of new technologies, ground-breaking machinery and equipment, cutting-edge products, systems and services, and more. Plus, for the first time this year, the Local Southern African Manufacturing Expo is incorporated within Electra Mining Africa.

MBA: What can you tell companies that are undecided about participating in future Electra Mining events? SE: With over five decades of experience and as the largest trade show of its kind in Southern Africa, Electra Mining Africa presents a very unique platform for bringing together related industry sectors all under one roof. Large organisations and SMMEs are represented across the areas of mining, electrical, automation, manufacturing, power and transport. They come to the show to trade.

To share and exchange value, whether that’s technology or products or solutions. They come to the show for five days to do business in one of the biggest trading markets that this country has to offer. Electra Mining Africa provides an outstanding opportunity to connect with thousands of potential buyers and decision-makers.

Electra Mining Africa helps stimulate trade in the industrial, manufacturing, and mining sectors of the South African economy.

Exhibitors make sales at the show, generate qualified leads, and build new customer and distributor partnerships. Visitors have the opportunity to see, evaluate and compare the latest products and services that meet their business and operational needs. What better way to bring a brand to life: on the floor of an exhibition where you’re engaging with your target market face-to-face. It’s a unique value proposition to participate in an exhibition like this.

3 Mining Business Africa | July- August 2024

Electra Mining 2024

Exhibitors are able to gain a deeper understanding of their target customer by getting firsthand feedback as the visitors interact with the products and services promoted on the stands. Participating can drive sales and brand recognition by exhibiting alongside the biggest names in the business, with access to the 30000+ industry professionals who are visitors to the show.

With Electra Mining Africa having achieved ongoing success since the inaugural show in 1972, the fact that many companies have been exhibiting at Electra Mining Africa since the first show thus underlining the success they have achieved at the shows over the years, and there being no better endorsement of the show than the almost 50% of exhibitors who had already rebooked their stands for the 2024 show, even before the gates had closed on the 2022 show, are all positive reasons why companies should participate in future Electra Mining Africa events.

Munters (Pty) Ltd 22 Angus Crescent - Longmeadow Business Estate, Johannesburg, Gauteng 1610 South Africa Tel dir: +27 11 997 2000, Mobile: +27836333764

Electrostatic Precipitators (ESPs) for Mining Projects

Electrostically clean, particulate free In a coal-fired power station, the use of electrostatic precipitators, together with scrubbing systems, to remove particulate matter and other contaminants minimises solvent loss, reduces maintenance requirements, and optimises energy consumption. he reduction of flue gas emissions from T processes is cardinal to contemporary mining operations, where sound reporting has become centrepiece.

ESG

This is not just about tick-box environmental compliance; it is also an operating expenses (OPEX) matter. So, doubtless, mining companies should be more meticulous in the selection process of techniques they utilise to mitigate the impact of emissions.

Several options Talking about technologies, conveniently, there are several options mines can use to handle pollutant-laden flue gases. However, it is about what could work best in their respective circumstances, as the saying goes: There is no one-size-fits-all.

Carbon emission abatement Of course, when CO2 emission abatement is mentioned, what instantly springs to mind are scrubbing technologies.

Beyond question, such technologies are effective when incoming gases are free of undesirable impurities at the inlet.

On the other hand, when the incoming gas has solid particulate matter (PM), scrubbers falls short. Thus, for an effective carbon control process, cleaning incoming gases is essential.

Electrostatic precipitators Electrostatic precipitators (ESPs) are regarded as one of the tried and tested technologies employed to reduce PM from flue gases in off-streams and process streams in mines and other industries. One example of this application is discharging gases from a boiler steam plant in base metal and precious metal refineries.

In ESP, electrical forces remove the PM from flue gases. Typically, a high-source (discharging electrode) generating a corona current charges the PM, which migrates to the collecting plate (collecting electrode) and is removed.

There are some conditions in which dry separation is not possible due to the characteristics of the gas. In this case, wet electrostatic precipitators (wet ESPs) would be recommended. Generally, wet ESPs are ideal for separating the finest dust-laden water droplets and oil-containing exhaust gases, among others.

Essentially, wet and dry ESPs work on the same principle and design. However, the major difference is that mechanical rapping systems are used for cleaning the discharge and collecting systems in dry ESPs. On the other hand, in wet ESPs, due to the effect of the electric field, a film of liquid forms on the collecting electrodes that continuously drains off.

When is ESP a necessity?

Switching from another separation technology to an ESP would become necessary when tests indicate that a plant has PM emissions exceeding the limit. In fact, it is safe to err on the side of caution by cleaning the gas at all times, where the solids could be microns in size.

Serious implications The presence of PM has serious implications in two areas: potential penalties due to breaching environmental regulations and increased operating expenses (OPEX).

1.Environmental legislation The removal of PM and other pollutants from flue gas is in compliance with the respective requirements of environmental management. In South Africa’s case, the National Environmental Management: Air Quality Act applies. More importantly, this is in fulfillment of the Occupational Health and Safety Act (MHSA), which obligates mines to mitigate health and safety hazards that mineworkers are exposed to.

Fascinatingly, advances in technologies have made ESPs more efficient and cost effective in treating gas streams with sub-micron particulate. Where all fundamentals are properly followed, the process can achieve separation degrees of up to 99.9%, where the fundamentals are properly applied.

Wet and dry ESPs To cater for unique requirements in projects and preferences, ESPs are available in wet and dry options.

6 Mining Business Africa | July- August 2024

According to the World Health Organisation (WHO), PM is classified as a carcinogen. So, ESPs facilitate the provision of a safe working environment for mineworkers.

2.OPEX From an OPEX standpoint, Monoethanolamine (MEA) scrubbing systems are costly to operate on their own without effective cleaning. This specifically relates to experiences such as solvent loss, high maintenance, and high energy consumption.

For example, in a coal-fired power station, the presence of contaminants in the inlet gas stream can result in solvent loss. Besides, they can cause fouling of equipment such as heat exchangers in the scrubber system, prompting unplanned replacements or repair costs, which escalates plant maintenance costs.

Another consideration is that the presence of impurities in the gas can result in 30 percent more power consumption in an MEA scrubbing system. In addition, ESPs overcome airflow resistance experienced in technologies like conventional bag filters, which offer resistance to airflow.

Significant difference Generally speaking, recent experience with CO2 scrubbers in other industries illustrates the importance of the cleanliness of the gases entering a scrubber system. It has been discovered that some gases contain a high level of PM. Thus, ESP technologies present an opportunity to reduce the PM load at the inlet to a scrubber, ensuring cleaner air.

But what could work best?

Based on what providers of ESPs provide various solutions have told this publication that the main preferences of clients in mining and other sectors are low maintenance requirements and quick installation.

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GEECOM's Electrostatic Precipitators

GEECOM: your trusted provider of High Technology Solutions for Environmental Protection Systems shift towards the securitisWithationtheofglobal systems that aid in reducing an

organisation’s environmental impact, there is a growing consciousness towards the adoption of highly effective air pollution control systems by industrial enterprises across the board.

It is against this backdrop that GEECOM, a Southern African leader in the supply and installation of control and mechanical components for dry and wet Electrostatic Precipitators has, for more than 40 years, been working with both large and medium sized industries to help them combat polluted air in their environment. To date the company has helped a large number of customers with their cleaner air policies by having completed over 300 projects.

At the forefront of this success is a determined drive to improvement in terms of the equipment on offer as well as constant development and intro-

duction of new technologies which, in the end, provide for the achievement of better overall results.

The Company GEECOM prides itself in the provision of highly effective turnkey solutions that are tailor-made to meet the express needs of individual customers. The company’s team of dedicated experts currently work with organisations in the cement, paper and pulp, steel, chemical and petrochemical, as well as metallurgical and power generation industries to name but a few.

“We achieve necessary results through the provision of products, systems and services related to the field of environmental control, that have been designed and built around solid know how and experience in this area.

We believe that we are able to assist customers in achieving their own goals - and become environmentally responsible

8 Mining Business Africa | July - August 2024

companies,” states Justin Managing Director of GEECOM

Mischkulnig,

With a geographical footprint that extends across the Southern African continent, GEECOM works with customers by defining their specific requirements through relevant needs analysis and solution architecting.

From design to installation, and then maintenance as well as related services of installed systems, the company is a trusted partner for customers looking to harness the power of Electrostatic Precipitators as well as other emission control devices.

A GEECOM Solution GEECOM provides individual or complete services for the construction as well as refurbishment or upgrades of both dry and wet Electrostatic Precipitators.

Due to the sensitive nature of the build and design of these systems, the most stringent

GEECOM's Electrostatic Precipitators quality controls need to be undertaken, and it is with this that GEECOM has secured an ISO9001-2015 as well as ISO-3834 certification, and a Five Star Health & Safety rating by NOSA. As a single source supplier of both mechanical and electrical systems, each solution is designed and tailored for a client’s environment. A GEECOM system or product will aid an organisation in the cleaning of air through the removal of a number of harmful particulates found in most industrial processes.

“All of our systems are designed and manufactured locally making use of our computerised design tools. We ensure that every product we build is quality tested and checked before supplying to a client, and we achieve this through ongoing testing and the application of live process models to ensure optimised operation of each product,” mentions Justin Mischkulnig.

High technology is exemplified by the following main elements: Stainless Steel Collector electrodes which benefit the removal of precipitated dust during rapping actions as well as extended life-cycle periods.

Stainless steel discharge electrodes which promote the constant and long term operation of maximum corona and power input “Swing-arm” mechanism for Discharge Electrode rapping leading to longer propagation of the highest rapping forces Rapping hammers with revolving heads resulting in constantly changing impact points High Frequency High Voltage control systems comprising automation elements for higher average power supply and better regulation of the precipitation process

The Team GEECOM employs only the best in their field and its team of engineers are all in environmental control technologies, services and associated products. The company invests heavily in its people through ongoing training, mentorship and skills transfer.

Justin Mischkulnig adds: “In our industry you need to remain ahead of the pack at all times, and you need to ensure that the products and services you supply deliver on their promise there is simply no room for failure.No one understands this better than the GEECOM team and we all pull together

to develop and deliver innovative products that meet our customer’s exacting business needs.”

Each employee is required to buy-in to the four cornerstones of the business, that being: environmental awareness, quality, safety and health. These values have been determined as a yardstick for customer service excellence and the development and delivery of quality products. In addition to these cornerstones, GEECOM invests significant amounts into dedicated research and development initiatives.

Conclusion “There is no question that industry needs to adopt the use of environmental protection systems more aggressively, but with so many products in the market it may be difficult to settle on a single supplier. My advice to organisations in the market for a solution is to select a partner with proven high end technologies, a solid track record, qualified customer sites, and years of experience under their belt,” ends Justin Mischkulnig.

For more information about GEECOM its products and services contact +27 11 794 3801/6, email: info@geecom.co.za or visit www.geecom.co.za.

GEECOM Mining Business Africa DPS 2024.indd 1

03/07/2024 19:11

9 Mining Business Africa | July - August 2024

Manufacturing of Collector Electrode plates using continuous Roll-Forming machine

Electrical test field using in-house Electrostatic Precipitator unit

Corona effect at Discharge Electrodes

Collector Electrode Curtain (Stainless Steel Plates)

Installation of stainless versus mild steel plates

High Frequency Units (HFI) for ESP control

Construction of new Electrostatic precipitator including Explosion Proof panels

Specialists in Environmental Control systems including the following: Systems •

Electrostatic Precipitator

• Wet Type Electrostatic Precipitator (WESP) •

Bagfilter

Services • Consulting and Plant Review • Technical Audits and Inspections • Design • Project Management • Manufacturing • Installation and Commissioning • Maintenance Contracts • •

Training Courses After Sales Services

Mechanical • Electrostatic Precipitator Internals • Collector Electrodes: Mild and Stainless Steel • Discharge Electrodes: Stainless Steel G-Spike • Rapping Systems and Auxiliary Devices Electrical • High Frequency Control Systems • GEECOMatic Control Systems • Transformer Rectifiers • Rapping Controls • Auxiliary Elements Electrostatic Precipitator for Smelter Plant

ISO 9001-2015 and ISO 3834 certified

www.geecom.co.za +27 (0) 11 794-3801/6

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Wet Scrubbers

Diagram of a wet scrubber

A

ny product is as effective as its correct application. This is conventional wisdom that industry doyens share, and it is what leading manufacturers of wet scrubbers used in dust control for mining and other industries more or less echo in concurrence.

The message could not have come at a more perfect time.

Health hazards Currently, mine sites are a beehive of various activities—drilling and blasting, grinding and blasting, name it. Emissions from equipment for these applications are a health hazard to the worker.

Wide range of mitigation measures Thankfully, with unprecedented technological advances, mines have a wide range of hazard mitigation measures. However, this hinges on the wisdom of their choices in getting the most suitable solution to handle ultrafine particulate matter, due to the differences in dust properties. The health risk workers face when exposed to PM is highlighted in the article on electrostatic precipitators.

The options Mines use cyclone dust collectors, scrubbers, cartridge collectors, and conventional air bag house filters where there is a need for clean air free of vapours, particulates, and gases. Each of these options has its unique upsides and downsides.

Wet scrubbers Product selection is application-specific, depending on the end-users’ preferences.

However, it is generally agreed that wet scrubbers are most appropriate for dust with certain properties, which conventional baghouse filters cannot handle effectively.

Specifically, where cleaning a moisture-laden gas stream is involved, the wet scrubber would be the tool of choice.

Water as the medium Dry dust filtration extraction systems use filter elements. On the other hand, in wet scrubber systems, water or water-based media are the media used to collect pollutants from the exhaust stream. Generally, wet scrubbers work best where there is a need for an effective technique of cleaning or 'scrubbing' emissions to eliminate vapours, gases, and particulate matter (PM).

Ideal applications Usually, wet scrubbers prevail in the following conditions: 1. Combustible dust Wet scrubbers are ideal where the particulate being collected is combustible, involving combustible dust. Using water to eliminate the particulate, a wet scrubber minimises the risk of an explosion in the scrubber.

Of course, the level of risk depends on the type

12 Mining Business Africa | July - August 2024

of dust, particulate size, temperature, andconcentration.

Some would suggest outfitting dry scrubbers with safety equipment to deal with safety risks.

But can't this escalate the system's cost, defeating the objective of saving costs by purchasing conventional baghouse filters?

What also comes to the fore is that, in most cases, dust-related explosions in bag house filters are due to poor maintenance. However, where ongoing maintenance is to be carried out religiously, the exercise is costly.

On the whole, there is no question that in applications involving combustible dust, a wet scrubber eliminates the risk of an explosion.

2. Moist gas streams The sticky material in the bag houses blinds and filters, necessitating unplanned replacement costs. Empirical evidence from projects demonstrates that wet scrubbers handle this challenge well, achieving a separation level of 99 per cent of ultrafine particulate.

3. Abrasive slurry characteristics In dry extraction systems, the abrasive nature of the slurry can result in clogging and erosion of injection nozzles. For instance, the sticky material in bags houses blinds and filters, necessitating unplanned replacement costs.

This can increase maintenance costs.

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▪ Each products tailor-designed in collaboration with the customer to suit his/her specific needs.

▪ Designed to suite African, European and Asian standards.

▪ Easy to install, maintain and replace parts.

▪ IECEx (Ex db l Mb) and ATEX (I M2 Ex h l Mb) certified.

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Wet Scrubbers

Automated wet scrubbing The wet scrubbing industry has not been caught napping, left behind by the times. Manufacturers are answering the demand for automation by integrating automated wet scrubber systems into existing plants. These offer a wide range of benefits, mainly eliminating manual manpower involvement and thereby reducing exposure to equipment hazards and accident risks.

What is more, IOT detection systems monitor a system’s performance, leakages, failures, and energy consumption and share data in realtime or near-real-time from anywhere.

Emmissions at a Coal-Fired Power Plant

Reality check There is a reality check. For all their benefits, in fairness, wet scrubbers have downsides. The following are most often cited: i.High initial costs Obviously, the high initial cost is due to their durability. The most common material of construction used is stainless steel to handle corrosive liquids. On the other hand, bag houses, cartridge collectors, and dust cyclones are made of cheaper carbon steel. i.Higher energy costs Another plain fact: a wet scrubber—venturi scrubbers, in particular—has higher energy costs than a dry extraction system. This is given that more force is required to mix water with exhaust gas. Typically, high-horsepower fans are used to perform this task. i.Waste disposal Secondly, as a wet scrubber collects contaminants, the water gets dirty and must be

replaced to meet pollution targets. Besides, waste disposal comes at a cost.

Weighing up the options In the present atmosphere, the issue of initial cost versus long-term gain crops up when mining management is discussing procurement decisions.

While considering costs is the easy way out, what emerged from the discussion is that mining companies have to weigh up the potential consequences of industrial accidents due to settling for the cheaper option. A thorough risk and benefit analysis has to be carried out on the merits or demerits of a scrubber in a particular application. Now some food for thought:What is rational? Settling for a conventional air bag filter against the seemingly high initial cost of purchasing a wet scrubber and facing the consequences, or taking a long-term view?

Ultimately, a wise decision is worth weighing in gold. The adage ‘better safe than sorry’ resonates.

14 Mining Business Africa | July - August 2024

Where the objective is to address the inherent limitations experienced with a conventional air bag filter, a switch to a wet scrubber would be feasible. Some manufacturers claim wet scrubbers can remove up to 99 per cent of particulates that are too small to be caught in baghouses and cartridge filters.

Seeking expert advice Overall, it is important to avoid making a costly gamble by seeking advice first. It is important to ask difficult questions to manufacturers or a highly-regarded sage in the field. Would a wet scrubber be recommended?

Mainly, pollutants to be separated, particle size, and dust load in the emissions determine the selection of the scrubber type. Manufacturers of wet scrubbers concur that the following factors top the list of prominent client preferences for wet scrubbers: high water collection efficiencies, low water recirculation, minimum pressure drop, and high absorption efficiency for liquids and vapours.

Automated Weighbridge Management

Inefficient weighbridge systems fuel huge financial losses in stolen raw materials, as criminal syndicates exploit loopholes.

F

or sceptics that dismiss the need for improving weighbridge management operations as exaggerated, take this as a dose of reality: Power utility Eskom reported that nine people were arrested at the Kusile power station on 7 September 2024, for theft of coal and fraud.

Eight of the nine culprits were weighbridge operators employed by Eskom Rotek Industries, and the ninth was a coal truck driver. Coal hauliers were allowed to bypass the Kusile power station without offloading the ordered coal. The weighbridge operators would process weighbridge transactions without the coal haulier entering the power station to offload the coal. However, the Kusile Power Station would be invoiced and unknowingly pay for the coal ordered but not received.

They then resell the better-grade coal, while peddling poorer-grade coal to legitimate customers,“ said JustWeights, adding that this could run into billions of rands. Sadly, some big corporate buyers may be oblivious to this.

The Traditional Weighbridge System This problem reflects the shortcomings of the traditional weighbridge system in picking up discrepancies. Mines use weighbridges to verify the net value of ore or raw materials. They are used together with ERPM systems, which monitor business functions such as stock control and orders, and truck and driver identification. In addition, a software package compares the tonnage of the goods with an order.

The problem, though, is that the ERPM systems are not directly linked to the weighbridges.

Hence, situations that do not match the order always arise.

To deal with this, goods are physically accounted for, a process prone to human error.

The theft of coal at Eskom demonstrates that tampering and theft can occur. At best, a slow, outdated computer system is used.

Bridging the gap There is a need for a system that fulfils the following roles: bridge the gap between the tonnage of the raw materials and the order; and monitor the activities of weighbridge personnel and the drivers.

This incident could only be the tip of the iceberg. When one considers unidentified incidents, the scale of the losses from coal stock becomes ghastly. When one calculates the losses, the cost is incredible.

In an industry brief, JustWeights, a South African weighbridge automation solutions provider, laments that coal theft has grown worryingly. The company highlights the modus operandi of tampering or diverting coal by syndicates involved. The company noted the following malpractices: truckloads of coal are weighed incorrectly; good grades and poor grades are mixed; and coal is removed by syndicates to earn a profit.

“Oftentimes, the grade of coal ordered by a client is lowered, with the better grade held by members of an illicit syndicate.

Precision is key to accounting for every gram of loaded raw materials

15 Mining Business Africa | July - August 2024

Cloud-based Weighbridge Management for Mine Operators

Turning Weighbridge Management from Burden to Benefit With Tontrac Weighbridge Management Solution, production data is captured automatically and made available to mine operators and hauliers in the cloud via their PC or mobile device in real time. This results in a wide range of benefits that turn the weighbridge from a liability into an asset.

M

echanical weighbridges are used primarily as mechanisms of control and accounting invoicing. They have diverse applications in everything, from scrap metal to fast-moving commercial goods (FMCG) to mining to waste management. Particularly, these industrialsize scales are critical components of modern mining.

5.Elaborate and time-consuming Data generated over the weighbridge is typically stored on paper or in Excel spreadsheets and can take days or weeks to process, delaying billing and cash flow. This elaborate and time-consuming method is costly for mining, where time is of the essence.

Downsides However, despite their benefits, mechanical weighbridges have several downsides.

Specifically, these include:

Generally, these limitations call for a convenient way of managing weighbridges.

1.Bottlenecks They constitute a bottleneck to production and cash flow. No matter how large the stockpile is, it cannot be turned into cash until it has been moved over a certified scale.

2.Considerable investment Weighbridges are large and require a considerable investment in capital equipment and space. Investment in qualified staff to operate the weighbridge is also required.

3.Safety and security concerns Typically, processing a mine vehicle across a weighbridge can take up to five minutes or more. There are safety issues if drivers are required to get out of vehicles or weighbridge clerks are required to walk to the vehicle.

4.Space constraints Historically, the only way to increase weighbridge production capacity has been to install additional weighbridges. However, when space is a constraint, this is not always feasible.

The Tontrac Weighbridge Automation System Tontrac Weighbridge Automation System has proven to be a proven alternative to conventional methods of weighbridge management. It takes humans off the weighbridge and automates the processes of identifying drivers and vehicles, weighing, and ticket generation.

Tontrac Weighbridge Automation system provides several benefits, most prominently: Production time over the weighbridge (“wheels on wheels off”) can be decreased to less than 60 seconds per vehicle, massively increasing throughput over the existing weighbridge.

The system is safer and more secure as humans are removed from the decision loop.

Production data (stockpile, haulier, driver, vehicle, and order information) is captured automatically and made available to mine operators and hauliers in the cloud via their PC or mobile device in real-time.

Additional security features include biometrics, number plate recognition, and geofencing for vehicle tracking and control between sites, as well as waybill comparison between dispatch and receiving sites.

Inter-site transactions are processed automatically, and Weighbridge data is available instantly. This allows for immediate billing and accelerated cash flow.

At the forefront of Mine Digitalization Thus far, Tontrac is encouraged by the success of its weighbridge management solutions in mining and other sectors.

However, the company is constantly innovating its solutions to keep abreast of contemporary needs. This is evident in its investment in Mine Digitization.

Tontrac has been at the forefront of Mine Digitalization for over a decade. With the sudden, worldwide advent of “AI in everything”, the company is leading the implementation of AI tools in the mining sector.

Committed Team Tontrac Team Tontrac is committed to the pursuit of helping mining companies turn weighbridge management from an operational burden to a benefit. Contact them for suggestions on how to lead your mine operation into the 5th Industrial Revolution.

For further details, visit: https://www.tontrac.co.za/

5th

Transition to the 4th Industrial Revolution AI Powered Site Access Control | Weighbridge Automation | Remote Monitoring | Inter-Site Weighbridge Integration | 24/7 Field Service | Load tracking & Geofencing | Route Deviation Alerts

www.tontrac.africa

+27 11 465 9663 / 9783

sales@tontrac.co.za

ONYEN AI-driven ESG reporting software consolidates the complicated process of ESG reporting, facilitating compliance. This increases a mine’s prospects of attracting capital investment, improves relations with stakeholders, and meets the regulator’s conditions for the mining licence renewal.

I

n their respective mission statements, companies involved in different commodities in African mining all vow commitment to sound ESG reporting compliance in their projects. One mining company goes as far as pronouncing, "We strive to exceed stakeholder expectations.”

Such is the high value attached to ESG reporting compliance for contemporary mining operations. Stakeholders, including customers, employees, investors, governments, and the broader community, have a vested interest in how mines conduct business and have a bearing on long-term sustenance.

It is no wonder that mining companies are striving to achieve high ESG scores at all costs. Thus, they need to utilise effective tools.

Six months after demonstrating ONYEN’s AIbased ESG reporting software solution to a wowed audience during The Investing in African Indaba 2024, the Director of ONYEN Canada, Lauri Clark, reiterates the importance of effective tools. “The accuracy of the ESG scores is as effective as the tools used,” she stresses, urging mining companies to explore ONYEN’s solution.

Educated choices Indisputably, she raises a valid point.

Mining companies need to make educated choices regarding reporting tools. A high ESG reporting score can make or break a mining business. Chiefly, an ESG score has implications in the following areas: the renewal of a mining licence by a relevant government authority; the chances of accessing or attracting capital, determining the state of the relationship with the host

18 Mining Business Africa | July - August 2024

community, just to cite a few. There is more at stake.

Outdated reporting Unfortunately, the matter of fact is that mining companies are employing outdated reporting techniques. During the recent Junior Mining Indaba held in Johannesburg, the director of a mining and environmental law firm, Malan Scholes Attorneys, Hulmes Scholes, highlighted this. He lamented that the challenge confronting mining companies is not commitment to ESG reporting compliance per se, but reporting in the correct format.

Augmenting this perspective, another specialist at the event, Junior Mining Council founder and President, Fred Arendse, noted that frustration comes when companies fail to package ESG in specific and predefined ways.

AI-driven ESG Reporting Software

Unfortunately, though well-intentioned, compiling relevant data using traditional reporting methods can be a burdensome, errorprone process, which affects the integrity of the results.

ONYEN AI-driven forthright and impactful reporting Conveniently, the ONYEN AI-driven reporting software solution provides a practical alternative to traditional reporting techniques.

“Our solution facilitates forthright and impactful reporting for mining companies to thrive in an evolving ESG landscape,” affirms Clark, pointing out that the solution gives organisations the edge in several ways, particularly the following: 1. Comprehensive and accurate data collection Utilising the capabilities of AI, Onyen software compiles vast amounts of data from departments in different locations. This simplifies the task of processing and analysis, offering meaningful insights into organisations and ESG performance. On the whole, the software ensures comprehensive and accurate data collection 2. Risk Mitigation Accurate information is central to mitigating the risks associated with climate change and biodiversity, loss, workforce safety, and corporate governance. With Onyen’s reporting system’s advanced analytics and predictive modelling, mines can identify potential risks before they become too complex to manage.

Through this, companies can implement targeted mitigation strategies.

3. Enhances access to capital investment By consolidating the reporting process, Onyen AI-driven software enhances the credibility of disclosed information. This transparency fulfils the expectations of socially-responsible investors, increasing the likelihood of attracting capital.

4. Adapting to evolving regulations Flexible and scalable, Onyen's ESG reporting system helps with internal gap analysis. It allows organisations to adapt seamlessly to evolving regulations, remaining compliant without overburdening resources.

5. Clear and transparent communication As a result of enhanced ESG reporting, a miner fosters relationships and builds trust with stakeholders through clear and transparent communication of sustainability initiatives, performance, and long-term goals. In the end, corporate values exceed stakeholder expectations.

6. Smooth transition to a more sustainable and responsible Designed for ease of use and compatibility with various enterprise processes, Onyen seamlessly incorporates ESG reporting into existing business processes. Thus, the software minimises disruption to day-to-day operations while maximising efficiency in data collection and reporting. By eliminating the need to overhaul their IT infrastructure, it allows for a smooth transition to a more sustainable and responsible business model.

Competitive edge Without a doubt, with a wide scope of capabilities, ONYEN’s AI-driven ESG reporting solution can give African miners a competitive edge in ESG compliance. In this manner, they can achieve the following: increased prospects for attracting capital investment; long-lasting and mutually beneficial relationships with stakeholders; and, above all, a good reputation Last but not least, another food for thought worth considering came from Arendse: “Early adherence to ESG norms would lower costs and reduce future stress.” What about adopting this tried and tested software at project inception to run through the life-of-mine?

The team at ONYEN is ready to address the needs of potential clients in African mining regarding ESG reporting. “We are committed to enhancing seamless, adaptive, and convenient compliance in ongoing projects in African mining,” Clark declares.

https://www.onyen.com/

19 Mining Business Africa | July - August 2024

Crushing and Screening

Sandvik Rock Processing Solutions’ focus on eco-efficiency ensures customers can process rock using the least possible resources.

Sandvik Rock Processing’s range covers a wide spectrum of vibrating equipment, including screens and feeders for all types of applications.

V

isitors to Electra Mining Africa this year are looking for crushing and screening solutions that will boost productivity while enhancing sustainability – and Sandvik Rock Processing Solutions has what they need. Exciting developments in the company's integrated offering of crushers, screens, screening media, lifecycle services and digital technologies will be on display with the company’s competent team on hand to share technical information and insights.

According to Tarynn Yatras, Vice President for Sales Area Africa at Sandvik Rock Processing Solutions, the lineup will include a working demonstration screen with digital connectivity.

Yatras highlights how the company’s pioneering technology is driven by its aim to advance the world through engineering.

“We lead the way in eco-efficient rock processing, and will be talking to our visitors at Electra Mining Africa about how we help to drive their productivity, profitability and sustainability,” she explains. “Our wide range of quality products are combined with lifecycle services to give customers fully integrated solutions across the crushing and screening process.”

The focus on eco-efficiency ensures customers can process rock using the least possible resources. In addition to the multi-function test screen on the company's exhibition stand, visitors can inspect and discuss the Sandvik screening media and cone crusher that will be on display.

“Another exciting element of our Electra Mining Africa presence will be the digital technology that enhances our equipment’s performance and longevity,” she says. “Our automation and connectivity system (ACS) will be on display, as applied to our cone crushers (ACS-c) and our screens (ASC-s).”

These connectivity systems link back to Sandvik’s digital SAM platform, which uses data to drive insights, support and performance.

Visitors can view the products and see the technology in action, she says, learning more about remote condition monitoring of machines and related service offerings.

She highlights the value of customers being able to monitor both their crushers and their screens on the same digital platform – given how closely these phases of the comminution process must operate. This opens valuable opportunities for

plant optimisation, especially with the depth of expertise imbedded in the Sandvik Rock Processing Solutions teams around Africa. The SAM platform also allows a user-defined data selection, to suit the particular role in the plant – from management to operator.

“Among our continuous improvements in condition monitoring has been an upgrade from wired sensors to self-powering sensors on our screens,” she says. Local digital experts and those from Sweden will be available on the Electra Mining Africa stand to discuss the systems in detail – including the range of benefits that customers can derive.

“Customers are also looking to ways to achieve their climate change goals while reducing costs, and we will be showcasing how we promote decarbonisation by reducing energy use through equipment optimisation,” says Yatras.

“Our vision – as a leading player in the mining sector – is aiming for a more circular economy while driving productivity to extract maximum value from resources.”

This is achieved through the integrated offering of crushers, screens, screening media, lifecycle services and digital technologies. Added to this is Sandvik Rock Processing Solutions’ extensive support footprint across the continent – close to the customer with world class local facilities and expertise.

Visit Sandvik Rock Processing in Hall 6 Stand C22.

Sandvik Rock Processing’s design and engineering process involves close collaboration with customers to understand their specific needs.

Sandvik Rock Processing’s digital technology enhances equipment’s performance and longevity, opening valuable opportunities for plant optimisation.

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Mill Lining Solutions

Take on the unique challenges at your mining operation and positively impact priority KPIs.

M

E FIT System is our integrated solutions program for large mining operations. it focuses on creating value for mining processes by quantifying the impact of their solutions while improving key productivity indicators in mineral extraction and processing. Our ME FIT program solutions are made possible through mutual collaboration between our clients and the ME Elecmetal multidisciplinary team.

By having an in-depth understanding and knowledge of each site’s operational issues we are able to positively impact their priority key performance indicators: productivity, reliability, availability, safety, efficiency and / or energy consumption. We align with the priorities of our customers, positioning ME Elecmetal as a true strategic partner in mining.

Products and Services that Make a Difference Mill Liners Grinding mill liners are subjected to severe impact and high abrasion. They must be manufactured using the best technologies and designs for superior strength and durability. That is why we make sure we offer customers the best possible solutions for every challenge and mill type.

ME Elecmetal analyzes customer operations to determine the ideal combination of design and materials to achieve the optimal performance of their equipment. Whether it is an AG, SAG, ball, tower or rod mill, our innovative liner and alloy designs deliver proven performance, while minimizing costly reline and downtime. We collaborate closely with operators and plant maintenance crews to

monitor wear performance and production rates, customizing each liner for the best possible performance. All variables are considered in this analysis — from the characteristics of the ore and the customer’s operative strategies to their production goals. We identify opportunities for improvement and adapt to challenges as they arise to offer solutions that exceed customer expectations. Our liners are manufactured according to the highest quality standards and state-of-the-art technology and engineering, resulting in the most reliable, lowest total-cost-ofownership- solutions for our customers.

Grinding Media ME Elecmetal designs, manufactures, and supplies the highest quality forged steel grinding media for SAG and ball mills in the world.

21 Mining Business Africa | July - August 2024

Mill Lining Solutions

Our extensive field experience, engineering and consulting expertise enables us to accurately analyze operational data, so we can support our customers to achieve continuous improvement in their grinding processes. The process begins when we deliver the grinding media to your site and ends when your final product exits the mill.

Our experience and large-scale grinding media production capacity have positioned ME Elecmetal as a strategic partner in the global mining market. Our experienced and knowledgeable sales and application engineers can help you monitor and improve your processes by collecting and analyzing operating data, improving media charging practices and offering solutions to optimize your grinding media consumption and improve throughput.

Crusher Wear Parts and Safety Tooling ME Elecmetal is the leader in offering wear solutions to crusher operators. We provide wear parts for primary, secondary, and tertiary crushing applications for the mining, aggregate and recycle industries with optimal designs and alloys specifically developed for each application.

We will help tackle any customer challenge, while striving to maximize the benefits we provide. We can adapt to any type of equipment customers may have on site.

With a focus on safety, durability, and easeof-use, ME Elecmetal also offers a full line of Crusher Safety Tooling products designed to help you get the job done safer, faster, and smarter!

Our products include:

Primary corrals Dump pans Setting fixtures Crusher nuts Power shackles Spider hooks Customized solutions Optimization Tools and Services There is an increasing demand in the mining industry for technology capable of optimizing processes, equipment, and performance. ME Elecmetal believes there is always room for improvement. We focus on delivering tailormade technology solutions for grinding and crushing applications, with a complete offering

22 Mining Business Africa | July - August 2024

of optimization tools, including wear monitoring, to further improve efficiency and provide our customers with timely information.

ME Elecmetal’s technical support and training goes beyond standard services offered by other suppliers. These services include DEM and FEM simulation services, 3D laser scanning for wear analysis, reline optimization, continuous improvement programs, grinding circuit optimization, and more.

3D DEM Simulations FEA Simulations Load levels, water percentage, speed, liner design, ball mill size and bolt torque are some of the variables that come into play, and digitization allows these variables to be addressed individually, or in combination to gain a better understanding of the operation.

Contact Us Today!

For more information on ME FIT Solutions and to learn more about how ME Elecmetal can help you optimize your mining processes, visit www.me- elecmetal.com or call 480-730-7500.

Vertical roller mills can help mines achieve environmental compliance and reduce energy consumption in their fine-grinding applications.

By Jimmy Swira

T

hese days one can put a wager on encountering the following topics at a mining conference: the depletion of rich ore deposits; the high operating costs; the arduous task of complying with environmental regulations; and the increasing obligation to enhance safety measures.

The recent high-profile forum where these were discussed in depth was the 2024 Investing in African Mining Indaba, whose theme was Embracing the Power of Positive Disruption: A Bold New Future for African Mining. The underlying message to the industry was clear: Adopt to Prevail. And it has never been more relevant.

Crushing and Milling This call resonates with the current atmosphere of crushing and milling. In this sphere, conditions suggest the need for new techniques that can facilitate sustainability and cost containment. This is particularly true in secondary and tertiary grinding, regrinding, and fine-grinding applications.

The Challenge In these applications, using conventional comminution processes, such as SAG and ball crushers, to grind the ore to flotation fineness has become challenging.

Mostly, this encompasses two processes: first, coarse crushing, followed by SAG milling or wet ball mill circuits. Alternatively, multiple-stage crushing is followed by rod and ball milling.

Previously, grinding high-grade ore to achieve flotation particle size using conventional methods was relatively easy and more costeffective. Nevertheless, these days, significant variations in ore mineralogy (variant mineral ores) are common.

Unfortunately, to achieve flotation particle size, continuous usage of conventional methods with

these ore grades involves incurring high costs (mainly in energy consumption) and leaving a big environmental footprint (in terms of pollution).

Particle Size Particle size determines the efficiency of flotation. Hence, the comminution process must be effective. Loesche shared a review with MBA: "The particle size is critical for a sufficient degree of mineral liberation."

The Gap Based on the above, there is a gap in suitable grinding technologies for variant sulfur dioxide copper-gold ores to flotation fineness. The variant ores require improved fine grinding to achieve better recovery through flotation. This paves the way for opportunities for alternative methods.

The Alternative VRM comminution technology is one of the alternatives worth considering. The other one is High-Pressure Grinding Rolls (HPGR), which, comparatively, has a bigger footprint. VRM employs a particle-on-particle bed dry grinding principle. Using high-speed impacts to break down particles, the ore is cracked on the mineral lines to expose more minerals to the flotation process. Furthermore, in most operations, the VRM is paired with an air classifier.

There have been several studies whose findings underline the relevance of VRM technologies.

Loesche has conducted a number of them. In investigations, Loesche compared dry and wet grinding technologies on grinding performance and particle fineness. The findings suggested improved flotation performances of dry ground products, specifically VRM. Interestingly, findings highlighted that coupled

with an internal air classifier, VRM equipment increases the energy efficiency of comminution (low energy consumption), improves particle size flotation fineness (large reduction levels), and increases the sustainability of mineral processing.

Opportunities Generally, the VRM is used extensively in cement and coal grinding applications.

Significantly, for these commodities, the method offers more energy efficiency than tumbling mills.

These days, upliftingly, Loesche and other OEMs in the comminution area have been deploying VRM with significant success. This is based on results in projects where dry grinding was deployed in different commodity projects.

Benefits of VRM By and large, VRM offers the following benefits in fine-grinding applications: Compared with conventional milling equipment, energy consumption can range between 40% and 45% less than a wet ball mill circuit.

They achieve better liberation beyond the standard beneficiation processes. In some mills, feed from 80 mm to 140 mm can be reduced to 75 µm in one pass.

Reduced reagent consumption: cleaner concentrates need fewer reagents.

Environmentally friendly: VRM allows for coping with water scarcity. Besides, there is less need for water reclamation.

Compelling Case Isn't it clear that there is a compelling business case for mining companies to adopt VRM? VRM can enable them to achieve environmental compliance and reduce energy costs in their communition requirements.

25 Mining Business Africa | July - August 2024

Mill Linings Dynamic innovation maximum durability

www.tegaindustries.com

The MVR mill for dry application is a proven equipment over many decades in industry applications for grinding of hard to medium-hard materials. More than 3000 Gebr. Pfeiffer vertical roller mills have been installed in the cement, lime, gypsum, solid fuels-industry and in industrial minerals.

R

ising power costs as well as construction and consumable cost paired with declining grades and the need to process harder ores require a change in comminution equipment selection.

Reduced energy and water consumption are mandatory for enhanced sustainability. A dry grinding system that is well known and capable of achieving this is the vertical roller mill. Vertical roller mills are traditionally air-swept mills. The material being ground is dried, if necessary, and transported by a stream of air during comminution to the classifier mounted on top of the mill.

Those continuous operating mills are used for flexibly adaptable comminution and simultaneous drying very hard to medium-hard materials. The modern mill type is known in many industries such as cement, lime and gypsum industry as well as for grinding of solid fuels for power generation.

Dry grinding technology with vertical roller mills gives a substantial benefit in energy savings: the energy consumption is about 30 to 40% lower than that of traditional mill systems used in the mining industry The vertical roller mill is a highly flexible machine that simultaneously grinds, dries and classifies. Dry grinding is able to deliver a uniform size reduction with a narrow particle size distribution. The achievable product liberation size is in the range between P80 of 1 mm down to P99 of 20 μm. The reduction size ratio of up to 1000 is very high compared to traditional systems.

The secondary or tertiary crusher can then be omitted due to the large feed size capacity of the vertical roller mill (refer to Figure 1).

MVR 6300 C-6 cement mill with MultiDrive®, Cherat Cement Co. Ltd., Cherat, Pakistan

MVR 6000 C-6 cement mill with MultiDrive®, Siam City/Chip Mong Touk Meas, Cambodia

Figure 1: Ore processing with vertical roller mill (grey) vs. traditional grinding concepts (white)

Start-up and shutdown of this mill type is much easier than in traditional milling. In today’s energy-constrained world the energy use can be managed much more easily with the flexibility of a vertical roller mill. Also, dry grinding is the pre-condition for subsequent downstream dry separation in combination with reduced water consumption.

The MVR mill for dry application is a proven equipment over many decades in industry applications for grinding of hard to medium-hard materials. More than 3000 Gebr. Pfeiffer vertical roller mills have been installed in the cement, lime, gypsum, solid fuels-industry and in industrial minerals. This flexible equipment reduces energy consumption to enhance sustainability and improve the circuit’s overall emissions profile also in ore processing.

Depending on the ore body the grind size adjusted for coarse particle flotation (CPF) could reduce further grinding energy, produce coarser tailings and decrease the footprint of flotation circuit and solid-liquid separation.

MVR 6700 C-6 cement mill with MultiDrive®, CBMI Biskra, Algeria

The dry grinding of ore in the MVR mill results in optimum grind size and increased liberation. In the rougher stage downstream the MVR sorting and separation of tailings and grade material takes place with the target to produce tailings with very low content of grade material. The amount of material to be concentrated further downstream shall be reduced as much as possible.

Gebr. Pfeiffer’s MVR vertical roller mill technology offers the highest power density in the industry. The compact nature of the machine with everything included in an integrated design (including a classifier), is complemented by up to 18 MW of operating power, providing production rates of up to 7,000 t/h with a single mill.

MVR 6700 C-6 cement mill with MultiDrive®, Holcim Barroso, Brazil

27 Mining Business Africa |May - June 2024

Request a trial grinding now www.gebr-pfeiffer.com/mining

ROCK YOUR

RECOVERY RATE Discover the benefits of dry grinding for your mining operation! Delivering improved mineral liberation, Pfeiffer vertical mills increase your yields, cut your energy and resource costs, and generate less undesirable fines. They are also ideally suited to expanding your existing plant to meet new environmental regulations.

Take the efficiency test. Tell us about your ore – we’ll advise you and carry out dry grinding tests in our technical center before surprising you with the results of the recovery.

Rock your recovery rate – Getting it done! www.gebr-pfeiffer.com

Mobile Screening Plants

Heeding the call New mobile screening solutions offer convenience, cost-effectiveness, and sustainability to entrylevel companies

By Jimmy Swira

O

EMS in the crushing and screening space bending over backwards to serve the are evolving contemporary equipment needs of clientele in diverse sectors from compact (portable) to monster sizes. This can be witnessed in mobile screening niche market that serves start-up mining projects, quarries, and entry level and medium-sized contractors.

OEMs and their agents are introducing new products and services specifically tailored for this. This is what findings of a survey from Mining Business Africa indicates .

Endeavours OEMs are undertaking several endeavours to meet the requirements of this clientele.

Particular developments stand out and have been gaining traction exponentially - growth in rental business and automation. This is what Mining Business Africa observes from engaging contractors and OEMs. But first, what specific challenges are OEMs addressing?

Mainly, the following are the contractors’ concerns: i.Equipment doesn't come cheap There are screening machines are vital assets but then they can also be a liability depending on the financial standing of the end user. While big mining companies are well-resourced, for start-up mining companies and contractors, the initial investment can be deterrence.

In most cases, the cost outweighs the benefit.

Economics doesn’t allow it. Even worse, the ongoing maintenance and repair demands can escalate the cost of ownership. There is a need for a solution. ii.Safety, efficiency, and energy cost concerns There are three concerns.

First, regulators are adopting a zero tolerance towards safety breaches. That is if new regulations that are being introduced to improve safety are anything to go by.

This is obligating contractors to invest in improving safety at all costs, prompting purchase of new safety enhancing products (refer to an article contractor compliance in this issue). Unwittingly, this well-meant endeavour may come at a cost to a contractor.

Compounding matters, the design of old equipment may pose hazards to operators.

Usually, some, if not most old generation plants, is not outfitted with safety- features to meet new provisions in health and safety regulations.

This in itself is a hazard.

Second, in projects the expression ‘time is of the essence’ is more than a cliché. Contractors need equipment in optimal condition. Hence, equipment performance has to be tiptop at all times to meet their targets. Their clients need nothing short of results. Efficiency is paramount.

Third, in industries, energy - usually dieselconstitutes a big operating expense in mobile screening plants, just like in other mining equipment. The cost of diesel has been increasing due to geopolitical instability in the Middle East.

Of course, there is the fleeting marginal fall in price. But this doesn’t bring much joy.

Not only is diesel costly. Its continued usage releases greenhouse emissions. This makes contractors liable for polluting the environment.

Necessity the mother of innovation End-user requirements are evolving, and simultaneously OEMs and their agents are keeping abreast. Bearing testimony to the adage: “Necessity is the mother of innovation”, they have taken initiatives in the following areas: i. Energy efficiency and sustainability What apparent is that the OEMs have embraced energy efficiency and sustainability.

For instance, hybrid and fully electric variants are available. Some OEMS claim that their machines have low-fuel consumption engines. ii. Equipment rental (on-demand solutions) Equipment suppliers have increased their inventory for equipment rental. This approach is meant to meet contractors’ demand for specialised equipment. Leasing is a viable option rather than committing substantial upfront capital expenditure. This eliminates the financial burden of ownership.

them from harm’s way.

What is more, another safety-enhancing feature is pre-programmed delayed start-up features.

Increasingly, this is becoming part of the automation bouquet in new screening plants.

Relating to South African mining sector, this feature is recommended under the Mine Health and Safety Act (MHSA) regulations and Occupational Health and Safety Act (OHSA).

The second one is predictable maintenance schedules. Equipped with actionable data, fleet managers can monitor, remotely control and automate the screening process for better performance.

There isn’t a more convenient way of gathering information on the next phase of maintenance.

Predictable planning of machine maintenance breaks translates into improved machine performance, reduction of downtime, and ultimately, increase in productivity.

One of the classic examples of remote monitoring is OEM Sandvik Mining and Rock Technology’s new Peak Screening designed to enable screening productivity. It integrates remote monitoring and automation into the screening process.

Upping the game What is clear is that OEMS and their agents are upping the game in the drive to heed to the call of clients in market segment. With AI opening new frontiers, screening machines new groundbreaking capabilities are set to enter the market for commercial usage.

iii. Automation and digitisation New screening machines incorporate automation, digitisation, and remote monitoring (AI-driven controls, IoT connectivity). Through the convenience of real-time data collection and analysis, these offer three benefits at one fell swoop.

A mobile screening plant (Image credits; ELB Equipment)

The first one is safety. At the coal face of screening, where safety is cardinal, the remote control features enhance operator safety.

Machine operators do not have to be close to or touch plant components, removing

Equipment suppliers have increased their inventory for equipment rental. This approach is meant to meet contractors’ demand for specialised equipment.

Modular Mineral Processing Plants

For operations with short life of mines (LOM), modular processing plants are emerging as the ideal option. Particularly, this is in projects where equipment is needed within a short time.

By Nick Barnes

A

t any given point, there are fascinating developments unfolding in the African mining sector, which has a huge appetite for innovations.

One notable trend is the increasing shift towards modular plants for single-process applications.

Generally, this translates into quicker delivery times, installations, and operations.

Doubtless, there is no better proof of this trend than OEMs noticing a consistent in product orders from clients in the past decade. This is what a snap survey of ten organisations with huge clientele in African mining reveals.

Remote locations with a short life of mine This speaks volumes about why modular plants are suitable for open-cast operations with a short life (at most five years) in remote locations. The pre-engineered feature makes relocation easier when needed.

Naturally, casual observers might pose two questions: What could this shift towards modular plants suggest? Could it be a fleeting fad or a necessity?

Unqualified necessity Where time and cost are essential in single recovery processes, naturally, plants offering convenience are an unqualified necessity, not an option. This is due to the 'fast track' feature of modular plants.

Where does the convenience come in?

Firstly, the structure of a modular plant is a pre-engineered recovery system consisting of pre-assembled process units. This is ideal for single-process applications such as crushing, dense media separation, ore scrubbing, screening, grinding, gravity concentration, flotation, cyanidation, and dewatering.

Popular choice That is why, for most mine operators, it is a popular choice for fast-track production. The pre-assembled structure makes it easy to erect on-site, which minimises civil and infrastructure costs. While manufacturing and quality control issues are offsite, everything is delivered to the project site pre-assembled.

What’s more, potential process changes can be accommodated seamlessly, and installation is done by a skeletal team.

Precision engineering However, for modular processing plants to perform the task optimally, as desired, precision is needed in their engineering processes. And so, there are several things to be considered for this to be achieved.

'Don't fit a square peg into a round hole' One of the mistakes is expecting standarddesigned modular plants to perform beyond their capacity. Freddy Mahlare, head of process engineering at UMS, said this in a press interview last year.

“If a mine wants a 20 000 t/pm or smaller generic-designed chrome process, a modular plant could be suitable for this application.

However, if the same operation requires operating at increased throughputs and processing or producing challenging ores or products, then it would not just be a case of replicating the 20 000 t/pm module.“ The oversight with this assumption is that the modular plant design might overlook various engineering and process requirements. This could compromise process operability, increase operating costs, and reduce efficiencies, Mahlare pointed out.

30 Mining Business Africa | July - August 2024

This expression could fit the cliché, "fitting a square peg into a round hole" in engineering terms.

Critical steps Instead, Mahlare advises, there are critical steps for the modular plant to meet expected performance expectations, mainly the following: 1.Comprehensive engineering Therefore, just like with a fixed process plant, the design of an off-the-shelf or material processing plant needs comprehensive engineering to consider whether the ore body can be economically processed.

2.Capital expenditure Then comes the most important part of all: capital expenditure. The engineering process design criteria, safe access to operations, and maintenance of the specific equipment determine this.

The huge cost of oversight Nonetheless, there is a piece of sage advice: bypassing critical engineering can result in missing some steps. Eventually, it can become inoperable, requiring costly excessive maintenance, and associated cost implications for the end-user.

The Long and short All things considered, the long and short is: modular plants can work perfectly if applied within the correct selection criteria for a particular solution, considering the necessary engineering.

Care and Maintenance for Open Cast Mining Projects

An illegal miner (Image credit: Barberton Times)

Care and maintenance phase is a critical period at a mine that has huge implications on future operations. After lapsing, a mine can either thrive or stagnate, depending on how the phase is planned and executed.

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he volatility of the mineral commodities business compels open-cast mines to implement care and maintenance at some point.

In some cases, if not most, the situation is out of the operator's or owner’s discretion. This action is within the ambit of regulation. Nonetheless, mining companies are entirely liable for the consequences of the challenges.

The scope of care and maintenance When a mine is in a state of care and maintenance (temporary closure), the implication is that it will have stopped production due to several factors. This includes, but may not be limited to, technical, healthrelated (like during COVID-19 hard lockdowns), financial, environmental, or labour-related (in most cases, a strike). This is in the hope of resuming operations when conditions are ideal.

However, the operator or owner is not planning to close the mine permanently.

What could occasion care and maintenance?

The following are three factors that prompt care and maintenance: i.Unfavourable business conditions Unfavourable commodity prices can prompt a mine to go into care and maintenance. The resumption of services could depend on a rebound in prices.

During this time, they should be provided with care and maintenance.

Worse still, if this is for an indefinite period.

ii.Health and safety issues The hard lockdown that followed COVID-19 demonstrated how preventative measures can impact mining operations. They ceased operations for a few weeks, and where they did, the operations were at most skeletal.

Risks Care and maintenance cause some risks to the mine. A well-intentioned legal process can go wrong, resulting in unintended consequences if poorly planned and executed. Some of these issues are related to the following in surface mining:

iii.Labour action A prolonged strike with no parties— management and unionised staff—failing to reach a consensus can force a mine to go into care and maintenance. Operations can restart after an amicable solution.

1.Environmental In South Africa, under the Department of Mineral Resources and Energy, the Mineral and Petroleum Resources Development Act 28 of 2002 (“MPRDA”) is a reference point in miningrelated matters.

Far-reaching knock-on effects Care and maintenance impact the following: the owners and management of the mine; the workers, contractors, and consultants; and the surrounding communities and suppliers.

Basically, it leaves no stone unturned, beyond those directly involved in mining operations.

Under its ambit, Section 28(1) of National Environmental Management Act 107 of 1998 (“NEMA”) obligates “every person” who has caused or will cause degradation of the environment to take steps to prevent degradation or pollution from occurring, continuing, or reoccurring.”

This is a very tempting time, as laxity might creep in and the mine might take the foot off the pedal of diligence.

Laxity can creep in, leading to breaches of mining permit requirements (Water Use Licence comes to mind). For instance, the cessation of mining activities can result in flooding in surrounding areas due to the suspension of dewatering. Tackling this could delay the restarting of operations at the mine.

Inevitably, the knock-on effects of care and maintenance can be far-reaching if not wellplanned.

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Care and Maintenance for Open Cast Mining Projects Dewatering is an essential service that should continue. The mine operator should have provisions for dewatering.

This approach should apply to all identified risks of environmental degradation. In short, the mine should adhere to its environmental compliance obligations.

2. Security Care and maintenance can expose equipment to the risks of vandalism and illegal mining activity.

This was witnessed in South Africa during the COVID-19 pandemic hard lockdown.

During the lockdown, in poorly guarded mines, criminals had a field day wreaking havoc, vandalising infrastructure, and carrying out illegal mining activities.

Some mines had their equipment, like substations and process equipment, vandalised.

Even Transnet, which renders essential service to mines, lost kilometres of rail infrastructure, both communication cables and infrastructure.

Fixing damaged equipment can cost a mine hundreds of thousands if not millions.

From what has been observed in South Africa, dormant mines attract illegal miners called Zama-Zama in local vernacular parlance. Their activities can cause ground subsidence.

Thus, measures to enhance security should be beefed up. This includes the use of technology to carry out maintenance.

3.Fractious relationships with stakeholders Stakeholders may think the mine operators are using care and maintenance to serve their ends.

The community may be sceptical about the rationale, thinking the mine is chickening out of Mining Charter obligations. Contractors, usually small businesses, may incur income losses.

Strained relationships with the host community can stall progress where the community’s buyin on a critical issue is needed.

Emile van Druten, says, “It is absolutely imperative” for a mine to correctly communicate its care-and-maintenance plan to not only staff and stakeholders but also the affected communities and suppliers.“ Proactive planning The significance of proactive planning from the get-go cannot be overemphasised. Every aspect likely affected by the care and maintenance should be audited, and the envisaged consequences should be properly managed.

Proactive planning ensures a smooth transition from care and maintenance to the project resumption.

Central to seeking stakeholder consent is ensuring transparency through effective communication.

Unfavourable commodity prices can prompt a mine to go into care and maintenance.

The director of environmental consulting company Environmental Assurance (Envass),

YOUR PARTNER IN OPENCAST Opencast Mining | Drilling & Blasting | Bulk Materials Handling | Crushing & Screening

www.zizwe.co.za

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There is growing traction for remote monitoring as a predictive maintenance tool for equipment in African Mining projects.

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I and machine learning have allowed remote equipment monitoring to perform incredible tasks. Now, mines can monitor the performance of mission-critical machinery without physically dispatching personnel there.

For over a decade, Ramjack has been consulting in remote monitoring for clients in different sectors. A member of the remote monitoring team at Ramjack, Katrina Willey, Ramjack, has noticed an increase in uptake for remote equipment monitoring solutions from African mining.

Takeaways Based on Ramjack’s observation, corroborated by other organisations, three takeaways emerge from the penetration of AI and machine learning in equipment monitoring. These are mainly: i. Maintenance Using telemetry devices to capture fleet data, a maintenance team has real-time insight into machine health. Hence, over time, they can utilise AI algorithms that process all the loads of data to identify trends, enabling them to proactively schedule preventative maintenance. This optimises uptime. Case studies have shown that one hour of downtime on a production machine can cost $100kUS+. ii. Safety AI-powered systems can monitor various safety parameters across the mine site. These include but are not limited to instrumentation monitoring, fatigue monitoring, air quality, gas levels, and geotechnical monitoring.

Willey elucidates, “Using real-time sensor data and historical patterns, mines can identify potential safety hazards with AI, and set up automated alerts to prevent accidents.

For instance, if gas levels exceed safety thresholds in a particular area of the mine, automated ventilation equipment can be set to turn on and mitigate poor air quality. Then alerts can be sent to evacuate personnel or initiate emergency protocols.

Proximity detection and collision avoidance are also the benefits of AI.” iii. Production AI can analyse vast amounts of data from sensors, geological surveys, and historical production records, which can be used to optimise mining processes. These algorithms can identify opportunities to improve efficiency and optimise load/haul to minimise transportation costs and fuel consumption.

Execution of key decisions Generally, Willey says, the key to achieving successful productivity increases and safety performance improvements is real-time data to ensure the execution of key decisions on the ground. “The closer to “the face” good decisions are made, the more effective all the downstream processes will be.”

Streamlined Compliance and ESG reporting Beyond improved productivity and enhanced safety, AI and machine-learning capabilities can help industries achieve compliance and improve ESG reporting. “AI and machine learning take vast amounts of data and provide concise reports based on your parameters.

Compliance and ESG reporting become streamlined with centralised access to all data to create reports specific to regional requirements.”

Willey foresees this trend continuing as companies aim for equipment availability while ramping up production.

33 Mining Business Africa | July - August 2024

Green Ammonia for Mineral Extraction

The adoption of green ammonia could be a feasible and sustainable way for power generation plants to reduce emissions.

By Jimmy Swira

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he downsides of coal, as a fossil fuel, have been extensively documented and dissected countless times. Still, it is worth reiterating that industries like mining, power generation, oil, and gas must do their part in reducing Scope 3 emissions from their coalfired power plants. It is a matter of putting words into action. At the end of the day, results count.

‘Green’ ammonia through water-electrolysis Undoubtedly, the good news is that, progressively, the industry is transitioning from coal gasification and steam methane processes to green ammonia-powered turbines to reduce its footprint. ‘Green’ ammonia is considered a feasible and sustainable alternative to coal in power plants, given its low carbon impact. Green ammonia is produced using hydrogen, generated through water electrolysis, powered by renewable energy.

Conventional production of ammonia In contrast, conventional ammonia is formed by isolating hydrogen from natural gas.

However, for all its convenience, this process increases greenhouse gas emissions.

The International Energy Agency (IEA) says global ammonia production accounts for 1.3% of energy-related CO2 emissions.

Dose of Reality But there is a reality check amid the excitement with opportunities in ‘green’ ammonia: two obstacles.

First, the green ammonia process is energyintensive. And this does not come cheap. So, any venture has to make financial sense from a long-term perspective. Hopefully, as renewable energy prices fall, this will become cheaper.

Besides, while green ammonia energy is a viable option, there are safety needs to be accounted for. Owing to its toxicity and corrosiveness, green ammonia requires proper transportation and storage.

The World Economic Forum acknowledges that the development of green energy production is still in its early stages.This is because significant investment in infrastructure is needed.

34 Mining Business Africa | July - August 2024

Unquestionably, these obstacles can be turned into opportunities.

Progress Of course, we are not there yet. But there is progress.

Five years ago, the World Economic Forum’s Davos Agenda predicted that green ammonia would have a stake in the world's industrial energy mix. Then, it might have sounded as if it would take a lifetime.

Certainly, the industry buy-in is encouraging.

In South Africa’s Eastern Cape Province, a 5 billion dollar hydrogen production plant is under construction.

The project is scheduled for completion in 2026. Coal-fired power plant owners should be observing this development keenly.

This is a commendable development.

Doesn’t the journey of a thousand miles begin with a single step?

Reduce CO2 and costs: Ammonia Solutions from thyssenkrupp Uhde

mmonia is a highly versatile chemical compound that is used by many industries for a variety of applications. The mining sector uses ammonia for the extraction of elements (copper and molybdenum) and metals (nickel) from ores. Ammonia is employed to cleanse exhaust gases from smokestacks, removing sulfur oxides and NOx, thereby enhancing the efficiency of electrostatic precipitators. The chemical compound also serves to regulate the pH in water in the treatment of wastewater. The ammonia that is used in these applications is produced by the reforming of carbon-based fuels (coal or natural gas).

Despite its essential use, mining companies face mounting pressure to reduce their carbon footprint and to transition to more sustainable practices. With this in mind, thyssenkrupp Uhde has developed an ammonia production solution based on renewable feedstocks that is 100% CO2-free. Production of ammonia that is CO2free is designated as green ammonia. Besides climate considerations, other drivers of the move to distribute production of green ammonia from small-scale plants have been the desire for localised self-sufficiency, avoidance of high transportation costs and import or carbon taxes.

"Whereas in conventional ammonia plants, ammonia is produced by steam reforming natural gas, thyssenkrupp Uhde’s green ammonia process is underpinned by green hydrogen produced by electrolysis," says Nithesh Mohun, Business Development Manager at thyssenkrupp Uhde.

According to Mohun, the feedstocks for the green ammonia production are hydrogen, water and renewable power. Renewable power is produced by either solar PV, wind, hydropower or a combination thereof. Explaining green ammonia production, Mohun says, "Within the electrolysis plant, water is converted into green hydrogen by the application of direct electrical current. Nitrogen is produced in an air separation unit (ASU)."

For the production of green ammonia, thyssenkrupp Uhde has developed solutions with capacities ranging from 300 tpd up to 5 000 tpd. "Our smaller scale plants in capacity classes 300 tpd, 600 tpd and 1200 tpd are offered on a fully modularized basis," adds Mohun. The plants would be fabricated, preassembled and pre-commissioned as skids for easy transportation.

Limitation for modularization is typically the shipping envelope. Subsequently, larger plant capacities are primarily considered being executed on a stick-built approach.

Nevertheless, even greater capacities are further developed considering more modularization.

Mohun adds that the key is standardization to maximum extent in order to ease execution. The hydrogen and ammonia modular solutions are matched. For example, the 300 tpd module is paired with a 120 MW plant.

Modularization provides benefits in addition to the underlying technology. These include reduced implementation timeframes, improved quality control, reduced project investment cost through lower contingency requirements and greater risk mitigation through significant reduction of on-site construction effort and time.

Moreover, as the reforming operates with air, there is no need for an air separation unit. The modular nature of the GHR offers, amongst others, reduced implementation timeframes, improved quality control and reduced project investment. thyssenkrupp Uhde also offers conventional ammonia production plants up to 5 000 tpd based on Uhde ammonia technology with almost a century of experience and more than 130 plants built, resulting in total to about 50 million tons per annum equivalent.

Small-scale ammonia plants have the advantage of distributed production location and reduction of logistics risks and costs. The small-scale plant can be designed to service the immediate market and thus limit capital outlay and transportation of large consignments of the product as well as logistics risks in off-loading and storage.

Small-scale green ammonia plants can compete with conventional plants under the right frame conditions. The key drivers for green ammonia competitiveness are reduced capital expenditure, cost effective renewable power supply and stringent CO2 taxes and penalties. In most parts of the world renewable power is now more affordable than power produced from fossil fuels. Capital costs for green ammonia plants are falling with increased research and development efforts.

Governments and environmental organizations are strongly driving enforcement of CO2 taxes and penalties.

"Considering the above, green ammonia can already today reach price parity with conventional ammonia production, e.g. by leveraging CO2 incentives and eliminating the need to import ammonia over long distances," states Mohun.

When the project focus is on conventional ammonia production, thyssenkrupp Uhde offers the modular A01 and A04 series Gas Heater Reformer (GHR) solution with capacities ranging from 50 - 350 tpd. The GHR solution was developed in collaboration with Johnson Matthey. The system is based on gas heated reforming (GHR) technology with a pressure swing adsorption (PSA) system at the front end and thyssenkrupp Uhde low-pressure synthesis loop at the back end. The design is less complicated than a conventional primary/secondary reformer and is especially suited for small capacities with low ammonia needs and high transportation challenges.

The GHR is a cost-effective solution as it eliminates the need for an externally- fired primary reformer, the elaborate waste heatrecovery section and the consequent excess steam production.

About us: thyssenkrupp Uhde South Africa, the local subsidiary of thyssenkrupp Uhde was established in South Africa in 1959. We are your leading partner for the engineering, construction and service of industrial plants and systems.

Our solutions encompass the entire range of services for Fertilizers, Petrochemical, Oil & Gas, and others. Our experience spans 100 years and over six decades in Africa with an impressive reference list that extends throughout sub-Saharan Africa.

For more information visit: www.uhde.co.za

Lubricant-enabled Reliability for Mining Equipment

Chris Hattingh, manager of WearCheck’s lubricant-enabled reliability (LER) programme, says that taking proper care of lubricants can extend the lifespan of mining assets, and boost their operational performance exponentially.

At Steelpoort - a chrome mining project, WearCheck customer recently embarked on a reliabilityimprovement programme. WearCheck technicians identified soot levels to be exceptionally high engines used in LHDs. An audit was completed and recommendations for improvements were broken down into quick fixes, as well as medium- and long-term goals.

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ubricants play a critical role in keeping the component parts of industrial machinery moving and operating smoothly, particularly in the mining sector. Keeping the lubricants clean and contaminant free is a sure way to extend their lifespan, improve their function and that of the machines they lubricate, and save money on maintenance costs at the same time. This forms the basis of any good lubricant-enabled reliability (LER) programme.

LER is just one of the many services offered by condition monitoring specialist company, WearCheck, via its Lubrigard division.

In this article, Chris Hattingh, WearCheck’s Lubrigard manager, discusses a case study in which refinements to the filtration and lubrication systems were able to extend the life of a key engine at a mine.

Background At Steelpoort - a chrome mining project, WearCheck customer recently embarked on a reliability-improvement programme, which focused on the handling and management of commodities used in the mine’s production equipment (LHDs – load, haul, dump machines), namely fuel, lube, air and coolant. An audit was completed and recommendations for improvements were broken down into quick fixes, as well as medium- and long-term goals.

When examining the customer’s oil analysis data, WearCheck technicians identified soot levels to be exceptionally high on both the Cummins and John Deere engines used in these LHDs. These machines operate 80 hours a week and are serviced at around the 160 hour mark.

Attempting to push past this point would negatively affect the life cycle of the engine.

Due to high levels of wear, increased viscosities, and a significant spike in soot from time to time, these engines had to have their

their service intervals reduced from the OEM’s recommendation of 250 hours. The decision to service these machines comprehensively every two weeks, coupled with engine failures, became a big cost pressure for the mine.

The problem Soot is a by-product of combustion. Increased levels of soot could indicate many things but, in this case, WearCheck found that after the 160 hour mark, these air filters were heavily loaded with process contamination. The poor air/ fuel mixture no doubt caused the high soot levels, and an attempt to bring soot levels down was initiated.

The Standard FRG11 – Filter Housing

The graph below represents the soot values between services:

The red dashed line indicates the point of installation.

The solution The filter used by the OEM on this LHD was a Donaldson PowerCore. This filter has a conventional primary and safety filter set-up with a built-in pre-cleaner. Given that the oil reports were highlighting major problems at the air filter, WearCheck advised the client to substitute the PowerCore filter with another Donaldson filter, as it was found that the FRG series housing (FRG11-0241) of this model would be the right choice for this application. This filter was added to the NEZROTEK air precleaner.

Technicians hard at work inside one of WearCheck’s 14 laboratories. Mining, earthmoving, industrial, transport, shipping, aviation and electrical operations are among the many industries that benefit from WearCheck’s condition monitoring programmes.

The Standard FRG11 – Filter Housing

37 Mining Business Africa | July - August 2024

Lubricant-enabled Reliability for Mining Equipment The results Hatting reports that the results from this trial were instant. ‘After the first sample, we could see an improvement in the levels of soot, which got progressively better over time. This is what is referred to as an “optimised state”. Loosely translated, this means that the engine is basically happier than before.’

Hattingh continues, ‘One of the more notable trends was that of the Total Base Number (TBN).

Less harmful byproducts of combustion meant that the oil did not have to work as hard, thereby increasing the TBN to healthier levels.

‘On a side note, the pre-cleaner removed an average of 139 grams of process contamination over a six week period.’

Conclusion Hattingh was happy with the outcome of the filter change.

‘We have, since these results, marginally increased the size of the pre-cleaner to allow for more air flow and lower clean deferential pressure, which should allow for even longer filter life. This, in conjunction with lower overall wear and improved oil health, allows us to look at extending the drain In addition to LER, WearCheck is a leading provider of many interval. This will be a other predictive maintenance solutions. The company’s core consideration, however - for service is the scientific analysis of used oil, fuel and other now - the focus is on getting fluids, which entails analysing fluid samples for trace maximum life out of the particles, to indicate which component is suffering unusual capital-intensive components.’ wear patterns.

38 Mining Business Africa | July - August 2024

WearCheck’s other reliability solutions techniques include asset reliability care (ARC), transformer chemistry services and advanced field services (AFS) - nondestructive testing (NDT), technical compliance (TC) and rope condition assessment.

WearCheck Water tests wastewater, groundwater and surface water in areas surrounding mining and exploration sites.

Compliance with municipal by-laws and environmental safety standards allows for the safe disposal of wastewater into streams and rivers.

WearCheck’s footprint spans 16 world-class laboratories in nine countries across Africa, Dubai and India. The company services clients in many additional industrial sectors including renewable energy fleet management, aviation, maritime and more.

Please visit www.wearcheck.co.za, email support@wearcheck.co.za, call WearCheck on +27 (31) 700-5460, or contact Chris Hattingh on chrish@lubrigard.co.za or cell +27 (0)83 625-0808

Achieving Low No-Load Losses in Transformers Minimising no-load losses can lower operational costs in mining-specific distribution transformers. But the task requires paying attention to detail.

By Jimmy Swira

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hree scenarios present food for thought to mining companies in the power distribution area: escalating operational costs, including running (of which energy is prominent) and maintenance, and the imperative to reduce emissions. Naturally, the challenge mine management faces is how to achieve this simultaneously.

Opportunities Encouragingly, there are several options at the disposal of mining companies. One of the areas where opportunities lie is in the selection of distribution transformers.

Naturally, the question is how transformers, subject to no-load and load losses, enable this. Firstly, to get to the bottom of the matter, it is vital to appreciate the intricacies of no-load and load losses.

No-load and load losses An advisory to the industry from Trafo Power Solutions describes the two: “The losses of a transformer comprise two parts: no-load (or core) losses and load (or copper) losses. No-load losses are a constant and are independent of the power being drawn, while load losses vary according to the power being drawn.”

Relating to transformer losses, the International Electrotechnical Commission (IEC) standards stipulate thresholds for maximum allowable load and no-load losses.

Factors Determining Load Losses The main factors determining load losses are the winding material properties, including the diameter and purity of the material.

These two have a direct impact on the resistance of the winding materials.

“The greater the resistance, the higher the losses, as the resistance of the materials is measured by the temperature at which it is measured,” explains the advisory.

No-load losses No load energy loss occurs when a transformer is energised but not supplying a load. The transformer’s core has to maintain a magnetic field with low no-load losses, which can be a tough ask. Hence, they are usually optimised to have lower no-load losses. Ultimately, when the transformer is not heavily loaded, there are lower monthly electricity bills.

Procuring no-load transformers Based on the above, Trafo Power Solutions suggests the following factors to be considered prior to procuring a no-load power transformer: 1.Higher capital costs Though the monthly cost of electricity for no-load loss transformers is lower than that of load-loss types, the capital cost of a noload loss transformer will be higher due to the design requirements to meet lower losses.

However, this is only one thing; other factors are at play.

2.Design David Claassen, Managing Director of Trafo Power Solutions, commented on the subject in the company’s press release shared with Mining Business Africa recently. “The rated power of a transformer is usually among the key determinants of its capital cost, but there are various design differences that will also come into play,” said Claassen, citing winding materials and environmental conditions among them.

3.Lower operational costs After paying an arm and a leg for the transformer, the next issue to consider is the operational cost, which encompasses running and maintenance costs. “Running cost is essentially the cost of electricity, measured in kWh. These costs are affected by the efficiency of the transformer. All transformers have both no-load losses and load losses,” said Claassen.

Attention to Detail The process of selection can be elaborate, requiring attention to detail. And so, mining companies can seek advice from manufacturers to assess the capital cost, through data on parameters such as losses, winding material, and environmental conditions, to name a few.

The design of dry-type transformers from Trafo Power Solutions.

(Image credit: Trafo Power Solutions)

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Strip Wound & Folded Magnetic Cores

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istribution transformers are central to electricity distribution in mining operations, where power is needed in process plants, among other equipment. As process plants are energy-intensive, every kilojoule counts, and energy efficiency is critical.

No load loss Unfortunately, miners encounter the common issue of high no-load loss in distribution transformers, which is a costly burden. The logical approach is to switch to low-no-load loss transformer alternatives.

Nevertheless, this sounds simpler than it actually is, as no-load loss distribution transformer components are not made equal; specifically, this applies to core technology.

Alloy Magnetic Cores A South African company with a pan-African focus, Alloy Magnetic Cores (Pty Ltd.), a leading manufacturer of innovative, high-quality strip-wound and folded cores, has responded enthusiastically to this need. Jo Williams, the technical operations manager, says the company is raising awareness

about the relevance of its solutions, highlighting the significance of informed product selection.

One of the common misconceptions Alloy Magnetic Cores is seeking to clarify is no-load loss. Specifically, Williams explains that achieving suitable no-load losses (NLL) on transformers is not only based on the design of the core, but also on the material used to manufacture the core. “A wide range of material is produced worldwide with differing losses on the mother coil. Hence, selecting low-loss material while taking the destruction factor into account is important.”

And so, considering how material impacts the no load-loss factor, AMC‘s folded cores (Jencores) go through stress-relief annealing, which further lowers the losses on the finished core.

Meticulous material selection The team at Alloy Magnetic Cores employs a meticulous process to deliver the most suitable magnetic core for no-load-loss transformers.

®

The heart of your transformer is the core of our business!

Manufacturer of folded cores, strip wound cores, toroids, c-cores and evans to specifications.

www.amccores.com ISO 9001: 2015

Cnr. Simon Bekker & Crompton Road, Germiston South.

P.O. Box 9525 Elsburg 1407, Johannesburg, South Africa.

40 Mining Business Africa | July - August 2024

They ensure that the cores are built to customer specifications using suitable materials to achieve the NLL required.

“The material selected undergoes a screening process to ensure quality, the material is then sent through to manufacturing only after it has been verified. Over and above, as the company is ISO 9001 compliant, the team ensures complete traceability of material from start to finish.”

Enormous benefits Largely, adopting no-load transformers manufactured with Alloy Magnetic Cores’ HighQuality Strip Wound and Folded Magnetic Cores in projects offers massive benefits for mining companies, Williams guarantees. “Using a folded core over a mitred core, especially for smaller kVA’s (up to around 1MVA), can drastically alter the losses, owing to current movement around the core.

There are fewer “hot spots” on a folded core, which affects not only the eddy-current losses but the harmonics as well.”

Manufacturer of mitred and 90-degree ® stacked cores.

Tel: (27-11) 825 1010/1/2/3 Email: gail@amccores.com

Bulk Fuel Storage Tanks

Safe, secure and efficient fuel storage What happens from the refinery to the storage facility in a mine is the most worrying part of fuel management. And so, best practice starts with the design and construction of a storage facility to ensure the fuel is of expected quality while minimising loss and waste.

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bulk diesel storage facility is a necessity onsite. Its convenience cannot be doubted.

Imagine the convoluted administrative process and the huge costs incurred through manually filling vehicles.

However, the process of designing and setting up a storage tank may seem like an inconvenience if not well managed. This is from product safety and security, and cleanliness perspectives.

Hazardous substance This is because diesel, flammable liquid, is classified as hazardous substance. So, one can understand the layers of legal compliance requirements and processes that mine operators must adhere to.

A diesel storage system can be a risk to the health and safety of employees, the general public, and the surrounding environment.

Measures to mitigate adverse impact Therefore, a mine should have measures to mitigate the adverse impact of its diesel storage system on the health and safety of employees, the general public, and the environment. In this case, it is imperative to get the correct equipment, maintenance processes, and asset management regulations in place.

Necessary approvals The most fundamental step is getting the necessary approvals from the relevant authorities. Admittedly, this can be frustrating and viewed as unnecessary red tape for a business desperate to start operating.

These seemingly onerous measures are in compliance with the Occupational Health and Safety Act, governing the safety of employees and the general public.

Fuel handling challenges After the installation and the tank is good to go, the biggest challenge is sound fuel handling.

In most cases, fuel from refineries and petroleum companies is compliant. The way fuel is transported and stored can compromise quality.

This is a point John Evans, Wearcheck’s Diagnostic Manager, raised in the June/July Edition of Mining Business Africa. “One of the first things to identify, is what we mean by “quality diesel” - let us not confuse poor quality with dirty, wet or adulterated fuel. It is extremely unlikely that a single drop of diesel leaving South Africa’s refineries does not conform to the SANS standard for the quality of diesel. It is from this point that the problems start, with poor transport methods, poor handling, sloppy storage and corruption. A wide variety of engine problems can be traced back to contaminated diesel,” he observed. i.Contaminated fuel Contaminated and inferior-quality fuel can damage or reduce the life span of a vehicle's engine. It causes reduced engine output, increased fuel consumption, ignition difficulties, and irregular exhaust gas temperatures, among others.

The following are some of the causes of poor fuel quality that should be avoided:

The regulations may vary from country to country, but they are meant to achieve a similar objective. In South Africa’s case, the National Building Regulations spell out the requirements for building plan applications and the list of standards to meet to get approval from a local authority. This is where a rational assessment is needed to establish whether the facility complies with the requisite standards of safety and environmental protection.

When fuel is diluted or mixed with water; Sometimes, use of inferior additives.

The deterioration of poor breather and filtration systems on tanks Poor maintenance practices.

These can result in rust, dirt, moist air, water, algae, or sludge accumulating in bulk tanks.

Best practice in bulk fuel storage ensure good quality and clean fuel for a mine’s optimal performance.

The rational assessment is submitted with the application to obtain approval for the storage of a hazardous substance. It takes into account the risks that hazardous substances stored or handled present.

i.Fuel loss Where humans are manually handling fuel, fuel loss occurs due to theft or waste due to errors.

In fact, fuel theft is said to be the most pervasive form of fuel loss in African mining. Estimates say that 8% of fuel inventories are lost to theft.

The rational assessment covers a several critical elements.

These are the properties, characteristics, and behaviour of liquids during storage. Generally, the basic ways of reducing risk from the liquids are through the sound design, layout, operating procedures, construction, and implementation of maintenance regimes.

Bearing in mind the significance of fuel, sound fuel inventory management is important at all times. It is encouraging that there are solutions to mitigate this.

The advent of software, that enables fuel monitoring or smart fuel management, and

monitors fuel volumes in near-real time is said to minimise losses. This is based on interviews this publication conducted with providers of these technologies in previous editions. Typically, data on trends in fuel usage informs actions to be taken when irregularities are identified, averting huge losses.

Sound fuel management the standard practice Considering that energy, of which diesel is one of the sources, is used in mining, sound fuel management in bulk storage facilities should be standard practice at every point. Adopting effective measures to mitigate contamination and reduce product losses should be prioritised.

Mining companies do not have the luxury of tolerating these costly errors.

Environmental regulations related to fuel storage (South Africa) The Environmental Management Act, No. 107 of 1998, obligates organisations that handle bulk fuel to be conversant with the following: An environmental impact assessment (EIA) is performed before the installation of above-ground or underground diesel tanks. Furthermore, underground tanks all require authorisation, no matter the storage size of the diesel tank.

An environmental management plan is also needed for decommissioning diesel tanks to ensure safe removal and pollution prevention.

Response strategies for diesel tank spills include emphasising protecting human health and restoring usability.

Aboveground tanks need to have a bund, (a surrounding wall that can contain at least one-third of the tank’s contents).

As part of diesel tank maintenance, companies must hire engineering experts to inspect tank valves, flanges, and pumps to ensure no leaks.

Underground tanks must be placed in a contained hole sealed with concrete. The space around the tank is filled with an immovable material to prevent chemicals from leaking into the earth.

The act also stipulates that a tank is required to be: chemically compatible with the hazardous substance being stored in it. protected from, or resistant to, all forms of internal and external wear. be vibration, shock, and corrosionresistant. have a stable foundation or support structure suitable for all operating conditions. be protected from fire, heat, vacuum, and pressure, which might cause tank failure. be sized to align with storage requirements.

Customisable Bulk Fuel Storage

F

uel quality could be an aspect mining companies may overlook as they intensely focus on achieving big numbers in revenue.

However, this oversight could prove detrimental; poor fuel quality damages equipment, which results in costly downtime to production. What’s worse, unwittingly, it causes increased emissions, in violation of environmental regulations.

Understanding the unique challenges the mining industry faces in fuel management, PETRO Industrial Solutions, as a seasoned leader in the field, goes beyond the call of duty. Unlike competitors, the company does not just sell tanks, but comprehensive fuel storage solutions specifically customised to individual mining operations. “Our expertise in fuel storage means you can trust us to provide systems that minimise downtime and protect your operations,” PETRO Industrial Solutions’ Operations Manager affirms, as he highlights relevant speciality, a customised approach, and a commitment to quality assurance as the company’s strong points.

Relevant speciality

PETRO Industrial specialises in robust selfbunded, above-ground fuel storage tanks, designed to ensure fuel quality and reliability.

The tanks are built to withstand the demanding conditions of mining environments. Compared to traditional externally bunded tanks, these offer superior flexibility, easier maintenance, and are more environmentally friendly and cost-efficient.

The company has a wide array of self-bunded storage solutions, from small-scale tanks to extensive tank farms. These range from compact 1,000-litre Cube tanks to expansive 75,000-litre containerised tanks that can be scaled up to form tank farms.

Certainly worth pointing out, the storage solutions’ most unique feature is versatility.

The tanks and dispensing units are designed to handle a variety of liquids, including diesel, engine oil, hydraulic oils, lubricants, and waste oils.

iPETRO Fuel Management Systems

More to the point, knowing that every drop of fuel counts, PETRO Industrial Solutions empowers mines with the iPETRO Fuel Management Systems. The systems enable precise tracking of fuel consumption, identifying discrepancies, and reducing idling time, which translates into significant cost savings.

42 Mining Business Africa | July - August 2024

End-to-end customisation

It is worth pointing out that PETRO Industrial Solutions is aware that every tank for the project is distinct as it operates under different operating conditions and requirements. This informs the company’s approach to tailor-making solutions. “Our inhouse design and manufacturing teams deliver end-to-end customised fuel storage solutions. They collaborate closely with the sales team and the client to develop a comprehensive solution. This ensures that the exact product is manufactured,” the Operations Manager explains.

Quality, safety & compliance

Upholding quality, safety, and compliance, the company’s well-trained and certified teams follow stringent protocols to deliver superior fuel storage solutions. For instance, smaller self-bunded cubes are built in line with SANS 10131, and larger self-bunded containerised tanks are approved to UL142 standards to meet industry benchmarks.

Durability and reliability To ensure durability and reliability, the company implements the following key initiatives: Material Selection: Use of only carbon steel and stainless steel, known for their durability and resistance to environmental stress.

Self-Bunded Design: The double-walled, selfbunded tanks provide an extra layer of protection against leaks and spills.

Protective Coatings: The application of protective coatings reduces corrosion and rusting, particularly in outdoor or humid conditions.

Comprehensive Quality Testing In addition, leaving no stone unturned, the PETRO Industrial Team carries out comprehensive testing, covering Hydrostatic Testing, Coating Thickness Testing, and Vacuum Box Testing/Pressure Testing.

The dedicated team is present on-site during installation and provides maintenance support postinstallation. During installation, it ensures proper on-site preparation and correct installation.

Post-installation, the team provides training and best practices for handling and maintaining the tanks. Further, it attends to issues that may arise requiring on-site repairs.

Ultimately, firm internal quality management procedures, in addition to internal inspections, guarantee that high-standard tanks reach the client.

Supply chain Above and beyond the capability to provide end-toend, customised, comprehensive solutions, PETRO Industrial assures clients of its capability to provide the required products devotedly at all times.

Through direct manufacturer relationships, the company has an extensive global reach. This ensures the delivery of top-tier, reliable solutions to mining operations worldwide.

The go-to partner Through partnering with PETRO Industrial Solutions, mining companies are guaranteed robust tanks engineered for harsh conditions. Evident in the project track record, the knack for forging innovation and quality has positioned the company as the go-to partner for fuel storage solutions.

+27 (0)11 864 7758

Track record in mining projects Established in 2010, PETRO Industrial Solutions has built a reputation as a leader in the bulk fuel storage market. There is proof more concrete than the extensive portfolio showcasing esteemed clients from diverse sectors.

Mining is one sector in which it has built a reputation, spanning from local South African mining enterprises to prominent global players.

Over the past twelve months alone, PETRO Industrial Solutions has successfully completed projects for more than six different mines, each presenting unique challenges and opportunities.

Precisely, project highlights include the following: Supplying a small mine in Centurion with a single 2000-litre cube to power their machinery efficiently.

For a mine in Kriel, we delivered a series of four tanks, each tailored for different liquids including diesel, hydraulic oil, and waste oil.

engine

oil,

Completion of a project for a mine in Phalaborwa, 1.6 kilometres underground.

It involved designing two series of three connected S-cubes on skids for engine oil and hydraulic oil storage.

On a larger scale, one notable project was for a prestigious global mining company in South Africa. It involved creating a tank farm comprising 13 tanks —six for oil and seven for diesel— integrated with a custom-built pump room for efficient dispensing.

Beyond South Africa, PETRO Industrial has delivered a 16-tank fuel farm successfully to a leading mining and metals group in Guinea.

www.petroind.co.za

sales@petroindustrial.co.za

Wear Plates for Mining Equipment

Alloys of high-resistance It is not just a matter of lining but also of the right combination of materials applied. Where other materials have faltered in projects, high-alloy, low-carbon steel plates have proven to be the ‘real deal’ in offering reliable component wear protection.

By Jimmy Swira

I

n mining operations, when feedstock passes metal surfaces of material handling and process equipment, it causes significant abrasive wear. Without timely intervention, the cumulative damage can escalate too extensively.

Unfortunately, the ensuing downtime can force a mine operator to incur unscheduled repair and replacement costs to fix the problem.

Protective lining Thus, the plant engineer has to forestall this costly outcome. Usually, applying lining to offer protection is the most practical option.

However, unavoidably, with time, the liner’s thickness is reduced, requiring replacement, which can be a significant cost. Eventually, the more of this exercise, the higher the overall cost.

The Devil in the Details In fact, with component wear, the true cost is hidden in the details.

In terms of productivity, equipment manufacturer Cummins estimates that the

South Africa (WASA) stressed that it is vital to use heavy-duty materials. They referenced the

downtime of a mining dump truck can cost up to ~ USD 1,000 per hour. Generally, the total cost of materials due to wear in the mining sector could be billions of dollars annually.

advantages hard-faced wear plates or overlay wear plates offer.

Effective lining Obviously, there is no better option to forestall downtime and reduce unscheduled costs than effective lining. It keeps plants and equipment running at optimum production levels for long periods. Long-lasting liners can reduce the total cost of ownership, which is the cost of lining divided by tonnage.

High-alloy, low-carbon steel plates Made of specialised materials, hard-facing plates or abrasion-resistant plates protect surfaces of equipment or components from abrasive wear, impact, and corrosion in various industries. These plates significantly extend the lifespan of machinery and equipment exposed to harsh operating conditions. In the long run, they reduce maintenance costs and downtime.

Wear plates as liners Many products offer protection against extreme abrasion. Conventional wear plate materials made of steel are among them.

High-alloy, low-carbon steel materials contain one or more elements such as chromium, nickel, molybdenum, vanadium, titanium, and niobium. The alloy offers significantly longer

Sadly, conventional steel is known to give in to extreme conditions from feedstock.

resistance than conventional steel in harsh and abrasive conditions. It provides more strength and less weight; it is three times harder than mild steel.

This results in frequent relining of components, In the mining industry, wear can be attributed to 50% of the total maintenance cost (FullScale Simulation and Validation of Wear for a Mining Rope Shovel Bucket by authors Andreas Svanberg, Simon Larsson, Rikard Mäki, and Pär Jonsén).

which contributes to high maintenance costs.

Hard-faced wear plates For this reason, in an interview, recently, the team from engineered wear-protection solutions manufacturer Welding Alloys

Abrasive materials result in component wear of front-end loaders

Project success Increasingly, high-alloy steel is regarded as an alternative to conventional steel. In most projects, this type of steel has shown significant resistance to abrasive materials.

Hardox® Wear Plates

The Hard and Tough Steel You Can Rely On SSAB is a global steel company renowned for its leading position in high-strength steel and comprehensive related services. It offers tailored, innovative solutions across various industries.

W

ith more than 50 years of experience in supporting the mining industry, SSAB is highly equipped to serve the African mining market at any time and in any region with advanced wear plate solutions using its flagship Hardox® wear plate. Keenly, the company has been observing project rollouts on the continent with vested interest and is eager to contribute its expertise.

Transforming challenges into opportunities Of course, the African mining market has unique challenges due to many factors. In essence, SSAB helps transform a mining company’s challenges into opportunities.

“Most mines are always grappling with managing operational costs, with repairs and maintenance often at the forefront. Realising this, we aim to work with mines by emphasising that opting for a lower-grade steel product to perform this task can cost them more in the long run,” says Raymond Rautenbach, Area Sales Manager, Southern Africa.

Opportunity for upgrading This is why SSAB encourages clients to regard all areas identified as an opportunity for upgrading, where the existing “part” or “equipment” is improved. Thus, by utilising various grades of Hardox® wear plate, the

company can focus the upgrade on the most urgent priority. This could apply to reducing downtime, increasing the life span, or increasing productivity.

"Our commitment extends beyond providing the best quality steel; we position ourselves as a service-oriented company that offers comprehensive technical support, such as wear analysis, material recommendations based on mined mineral and advanced software solutions, to ensure our customers fully leverage the advantages of Hardox®.

This approach allows us to support the specific needs and challenges of our clients effectively,” Rautenbach says.

A vast array of mining-specific products SSAB offers a vast array of materials specifically designed to meet the upgrading requirements of mining clients. Its main products include Hardox® wear plate and Duroxite® overlay. Hardox® wear plates range in hardness from 450 Brinell to over 600 Brinell.

This range allows for tailoring the wear solution to the customer’s needs, maximising the desired benefit. It allows for wear-specific customisation in the wear-affected areas of mining tippers, trays, chutes, conveyors and

more. “Customers can optimise the service life of multiple pieces of equipment to achieve optimal productivity. Duroxite® overlay allows mine owners and operators to focus purely on sliding wear where impact is minimal. It can be used in combination with Hardox® to optimise the wear life of the desired equipment,” Rautenbach says, shedding more light on features.

Low total cost of ownership There is no question that SSAB’s wide product range caters to the vast needs of clients.

However, an inescapable reality is that there are hundreds of steel wear plate products targeting the African mining market.

“Essentially, by accepting lower-grade or mild steel in the equipment, you run the risk of unpredictable service life and breakdowns.

Most wear plate suppliers do not guarantee their properties and focus only on offering a plate that meets the required hardness level.

However, almost all wear applications require toughness, through-thickness guarantees and through hardness, which SSAB ensures with its different grades of Hardox wear plate,” Rautenbach says, assuring potential clients that a major advantage of Hardox®is the low total cost of ownership.

45 Mining Business Africa | July - August 2024

Hardox® Wear Plates The advantages of Hardox® wear plate Ultimately, the value that mines get from Hardox® wear plate depends on the outcomes a mine wishes to achieve, whether through reducing costs by minimising downtime and increasing service life, or focusing on output (productivity). In the main, mines benefit from using Hardox® wear steel in the following ways: i.Reduced costs Enhanced Durability: Hardox® wear plate is known for its exceptional hardness and toughness, which makes Hardox® highly resistant to wear and tear in tough applications.

This durability reduces the frequency of replacements and maintenance cycles and, ultimately, costs.

Improved Equipment Lifespan: By using Hardox® wear steel, the lifespan of mining equipment is significantly extended. This means less frequent downtime for repairs and replacements, leading to more consistent operations and output.

Reduced Maintenance Costs: The high wear resistance of Hardox® steel means that maintenance intervals can be extended, reducing the overall maintenance costs and downtime. By reducing one cycle in a year, a mine can have a significant improvement in both cost reduction and improved uptime.

Increased Productivity: With less downtime and mining fewer maintenance interruptions, operations can run more smoothly and efficiently, increasing productivity. Eventually, by focusing on time and costs to address all of the above, mines can significantly improve their performance. i.Increased Output Versatility: Hardox® wear plate can be used in various applications in the mining industry, including loading, transport, and crushing. This versatility allows for a more streamlined and efficient operation that can focus on, for example, hauling overburdens, where moving as much as possible for as long as possible matters most.

By choosing Hardox® 500 Tuf, the mine owner or operator can increase capacity by reducing the weight of the equipment while still guaranteeing its lifespan.

Predictable Performance: The consistent quality and performance of Hardox® wear plate ensure predictable service life, which helps in better planning and scheduling maintenance activities.

“We refer to this as predictive maintenance.

When you have a guaranteed service life, you can plan the replacements well in advance to avoid the dreaded breakdown that ultimately inflates the costs of any operations. This also allows mines to procure the required parts in advance to ensure uptime,” Rautenbach says.

An essential tool for stability Generally, installing Hardox® wear plate can lead to significant improvements in operational efficiency and cost savings in the mining industry. When choosing steel wear plates, mine owners and operators must look beyond the cost. SSAB urges mining companies to adopt Hardox® wear plate and get more value beyond the price. “Don’t consider Hardox® as an expensive wear plate but rather as an essential tool to provide stability in the most critical areas of equipment where maintenance and repair are often needed,” Rautenbach stresses.

50 years of Hardox® Wear Plate Since its launch in 1974, Hardox® wear plate has raised the bar in abrasionresistant steel, achieving milestones in different projects globally.

SSAB’s extensive knowledge of producing quenched and tempered (Q&T) steel grades resulted in the highly respected Hardox® wear plate, its premier flagship product.Hardox® wear plate is renowned for its unique hardness and toughness, making it the world’s first bendable wear steel.

This allows for reliable performance both in the workshop and in operation.

Hardox® wear steel is hard from the surface and deep into the material, extending service life in real applications several times compared to other AR materials. Toughness means it can also take heavy blows without denting or cracking.

Market needs are continuously evolving.

To keep pace, SSAB has constantly developed the steel over the years, producing new state-of-the-art grades such as Hardox® 500 Tuf, Hardox® HiAce, and Hardox® HiTemp.

Hardox® has a history of unmatched performance and a future of reliable productivity for anyone who uses this steel. It is not surprising that Hardox® wear plate has been the leader in wear steel for 50 years. SSAB is eager to create more milestones within the years to come, ensuring that industries experience the benefits of the reliability of its high-strength steel.

https://www.ssab.com/en/brands-andproducts/hardox

47 Mining Business Africa | July - August 2024

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Sarryx

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WGC 2025 Beijing Event

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Mining Business Africa (MBA) is Pan-African bi-monthly publication that focuses on latest developments in mining and allied industries in Africa. The publication covers the scope of critical activities from pit to part - mineral exploration (prospecting), mine planning and development, extraction, mineral processing, storage transportation, as well as beneficiation.

Mining Business Africa provides the desired mileage for companies looking to promote their products and services to a specific niche clientele in the African Mining Sector. Subscribers are located or at least involved in projects in South Africa, Botswana, Zimbabwe, Zambia, Kenya, Democratic Republic of Congo, Kenya, Tanzania, Ghana and Nigeria.

MBA is published by Media Icon, a company manned by personnel with a combined experience of 30 years in the publishing space.

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