Africa Mining Insight

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AFRICA Africa’s own Mining Journal July-August 2020 > Issue 4> Vol.#2

Solving the challenges of mining communications Pg.26

DURAPAC SafeDlock Jack Pg.22

C O N T E N T S 4

NovaFlex Custom Material Handling Hose Specialists

06 A zoom into Delta Hydraulics

10 Air percussion drilling for the Mining Industry

16 Morningstar solar controllers for protecting oil & gas operations and making mining operations safer


Cap Lamp With Integrated Missing Person Locator

22 LIBS chemical sensing applications in the mining and minerals industry


Figure 1 Example of rock | July-August Issue 2020

Figure 2 Examp

As always I welcome you to this edition of our wonderful magazine. I hope you will enjoy going through it. This edition features many topics which are very important in the miming business. Different mining equipment producers have pitched their products with us highlighting their specialties in producing the different products. With your acumen and knowledge of mining products, this will assist you in acquiring the products should the need arise.

Front cover Editor Goodwill Sibanda Writer Kennedy Chamu

Mining is very risky in terms of operation and demands very high safety measures. Mine safety comes with a lot of safety measures being implemented at every level. This takes into account the clothing and safety equipment in use such as, hard hats, gas detectors, safety harness, respirators, and missing person locators in the case of collapsed mines. There is nothing as horrifying as a miner trapped underground with no hope of being located and rescued. Safety always remains a concern especially in underground mining and this is why I took this time to write about it On June 6, 1972 a series of underground explosions occurred at Wankie Colliery number 2 mine in Rhodesia now Zimbabwe. The explosions caused 427 fatalities. The firm managed to pull out 8 people from the mine. The rest could not be located and the second explosions on the 7th of June rendered the mine unsafe for rescue operations. The mine was closed with 419 miners buried underground. This ranks as the worst mine disaster in Zimbabwe. Sales Lenox Marufu Roslyne Mangena Taniah Macholo Faith Mudara Mthulisi Nkiwane Prince TInashe Design & layout Peter Johnson Accounts Sharon Moyo Subscription Thato Ndlovu

landline +27110257031 Cellphone +27658159406

The other incident which happened a few years ago was the mine collapse in Chile. This trapped over 100 hundred miners underground. It took a dedicated team of mine rescuers to locate and bring the miners to the surface unharmed. Specialist equipment was used and of note was the missing person locating equipment the miners had which assisted the rescue team to locate them. In this edition we feature a product which is designed to locate miners at anytime especially when trapped underground. Cap lamp with integrated missing person locators (MPL). This can locate a missing person behind a solid rock wall making rescue operations much easy. The product a 2 in 1 device smart light consists of a LED cap lamp with an integrated missing person locator. The MPL sends a low frequency signal that penetrates the rocks and it is received and processed by the latest technology receiver device called Mini-Search 15. Rescue teams can use this device to locate users of smart light 05/M1. The device can locate a miner within a 30 meter radius even through solid rocks. This then makes the device a hand instrument in mine safety. In conjunction with the cap lap locator the firm has come up with cap lamp management software to monitor miners from the lamp room. This gives confidence to the miner and eliminates the fear of not being found in the event of a mine collapse. Since miners are faced with several risks in their occupation, investment in their safety should be prioritized at all cost in order to ensure production levels are maintained without disturbances. All hazards both physical and moral should be removed in order to produce a safe environment for the miner. Protective clothing and safety equipment should be availed to the miners for their protection. This will produce a health worker ready to go down and work without fear. Mine accidents are real and have cost lives like in the Wankie disaster. With new technology and the products pitched in this magazine this could be a thing of the past if mining companies are willing to invest in safety. Until our next edition enjoy your reading. Best regards

Editor G. Sibanda

Disclaimer: All material is strictly copyright. The magazine or any part thereof may not be reproduced or adapted without wri�en permission from the publisher: Africa Mining Insight welcomes material submi�ed for publica�on but retains the right to edit copy. The views expressed in the publica�on are not considered those of the publisher (Cleopas Projects), which accepts no liability of any nature arising out of or in connec�on with the contents of this magazine. While every effort has been taken in compiling this publica�on, the publisher does not give warranty as to the completeness or accuracy of its content. The publisher and the editor cannot accept responsibility for any loss inconvenience & damage that may occur there from. |July- August Issue 2020


NovaFlex Custom Material Handling Hose Specialists

Unlike many companies that compete in this sector, Novaflex® are exclusively a specialist hose manufacturer with a wealth of experience in heavy duty applications. Novaflex® hoses are installed around the world in a variety of mining, engineering and material handling applications. Novaflex® Slurry King hose offers exceptional performance in mining, quarrying and other extraction activities. Slurry King provides many distinct benefits when compared to other hoses commonly used for harsh applications such as mining slurry transfer. These include: •

• • • •

Exceptional abrasion resistance – which ensures longer service life and better value for money. A wide range of sizes from 2” (5cm) to 16” (35.5cm) inner diameters A high level of flexibility which saves time and cost Quick connection feature as standard Support and advice as standard

Slurry King is available with five different liners. Knowing which compounds are best for each abrasion resistance requirement enables Novaflex® to create longerlasting hoses for applications such as mining slurry transfer.


All Slurry King hoses have been abrasion tested to ASTM D5963 and ISO4649. Slurry King hoses offer a range of very good, excellent and superior abrasion, cut and gouge resistance; suitable for a variety of different applications.

service life. Hose wear always occurs on the outside radius of the bend, so the greater the bend radius, the lower the angle of impact and the lower the rate of wear. The optimum bend radius to reduce wear is ten times the inside diameter of the hose.

It’s not only abrasion that affects the performance and service life of a transfer hose. Bends, offsets, misalignments, expansion, contraction and vibration can be all in a day’s work for a hose, and the hose material and construction need to be flexible enough to cope.

The quick connection feature unique to our hoses means that fittings are faster to secure, which also contributes to reduced downtime and overall improved equipment performance. The design of our flanges namely the area for the bolt head which is recessed and locks the bolt in place is such that the operator needs only one wrench to securing the flanges. Most other ‘split flanges’ require that you hold the bolt head with a wrench while tightening the nut with a second wrench. It’s a small difference but it saves time and makes handling safer.

As well as a range of different products, Slurry King is also available in a wide variety of sizes from 2” (5cm) to 16” (40.5cm) with fittings (larger on request) which means that hoses can be used for a variety of different applications, across every continent, and in a variety of different scales of operation. Flexibility within the hose means that connections are easier to establish. This can be particularly helpful when attempting to align fittings and components together. The flexibility can significantly reduce removal and replacement time and cost.

As well as the standard Novaflex® abrasion-resistant mining slurry hoses, there are more wear-resistant and quicker installation options available too.

Even so, engineering as large a bend radius as possible into the hose system will help to reduce wear and increase | JulyAugust Issue 2020

DURAPAC SafeDlock Jack

“New Ba�ery Drive Technology” “Drive – Li� & Lock” Australian made SafeDlock by DURAPAC is not only a air hydraulic jack, but it also complies as a certified Vehicle stand . The SafeDlock has been designed and developed in close conjunction with key partners like Rio Tinto to produce a safer, more efficient and userfriendly jack. With over 10 models available ranging from 70 ton through to 200 ton , DURAPAC SafeDlock has now worldwide Patents covering its exclusive design & technology. Complying to the rigorous Australian Standards which call for a 3:1 safety factor ensure the SafeDlock complies as a approved Hydraulic Jack and also a certified Vehicle Stand. The latest feature of the SafeDlock is our “PowerDrive” Battery driven technology which is especially critical


when using large 150 and 200ton jacks. Safety is paramount on mining sites today and the PowerDrive allows the operator to simply drive the SafeDlock around the workshop or under the vehicle. There is no need to push the jacks around anymore says Sales Manager Frank Cimenti of DURAPAC. Operators can drive up a 7-degree incline or on rough terrain. The SafeDlock has 2 rechargeable batteries which will last a combined 8km before recharge which makes it a perfect choice for moving around a large workshop. (forward/ reverse, left and right wheel control).

under standards as a vehicle support stand. The SafeDlock has a patented Internal mechanical locking system which converts the jack to a certified safety stand. So, an operator with a SafeDlock would simply drive the jack under the truck, press the Lift button on the 5 metre remote control and then press the Lock button. Once the lock button is pressed and indicator would notify the operator that the jack is now a Safety Stand complying to Vehicle jack stand standards .

Many other jacks on the market use unsafe U Rings to hold the dump truck as a support, however Frank Cimenti cautions the use of these as they do not comply

Frank Cimenti DURAPAC

Drive – Lift & lock with SafeDlock See more on | July-August Issue 2020

A Zoom in to Delta Hydraulics Hydraulic Cylinders Delta Hydraulics was established in 1975 and is one of the the largest hydraulic cylinder manufacturer in the Southern Hemisphere with manufacturing facilities in Australia and Thailand. The plants can undertake the full cycle of design through to manufacture for: • •

Customised hydraulic cylinders Hydraulic cylinder repairs and refurbishment

Brands With over 2,000 customers in 30 countries Delta has manufactured or refurbished cylinders for many of the world’s best known mining brands including Caterpillar, Komatsu, Mitsubishi, Mitsui, Sandvik and Epiroc. As well Delta has deep experience in building customised hydraulic cylinders for specialist mining equipment OEMs in the sectors of surface mining, underground mining, vertical boring and tunnel boring. Customers include Elphinstone, Transmin, Load Quip, LoadPro and John Holland. Telescopic Cylinders & Hydraulic Rams Delta can manufacture or refurbish two to five stage single or double acting telescopic cylinders, as well as a wide range of rod /ram style hydraulic cylinders. Design Capability Delta has an experienced team of drafting and finite element analysis engineers with a combined 70 years experience in designing and repairing fit for purpose hydraulic cylinders. Procurement Capability Delta has an international network of suppliers enabling it


to procure a wide range of quality steel rod, steel tube, stainless steel material and seal kits to suit a myriad of customised hydraulic cylinder builds, repairs, and refurbishments. Manufacturing Capability Delta has a wide range of machines including: • • • • • • •

CNC Lathes & Milling Manual lathes CNC Grinders CNC Friction Welders Gun Drills Rotary Welders Skiving and Burnishing Machines • Induction Hardening and Quenching • Electrical Discharge Machine • Hard Chrome Plating • Paint Delta’s machine capability enables it to skive and burnish bores with Internal Diameter of up to 500 mm, and 9,000 mm in length. Delta has the capacity to friction weld clevises to rods up to an Outer Diameter of 300 mm and a length of 3,400mm.

cylinders. These cylinders incorporate oil extension and retraction ports which are drilled through the rod or in the annulus of the bore to enable the flow of hydraulic fluids that power the piston to flow internally without the need for external hoses or line tube. Ceramic Treatment of Hard Chrome Plating Delta’s proprietary ceramic treatment of hard chrome plating surfaces extends the corrosion resistance by tens of thousands of hours and is ideal for highly corrosive surface and underground mining environments. Further information can be found at our website John White Delta Hydraulics Pty Ltd Phone: +61 3 6420 6900 Email: Web:

Annular & Internally Ported Cylinders Delta designs, manufacturers and refurbishes annular ported telescopic cylinders and internally rod ported hydraulic | July-August Issue 2020

ILMEG Dry Rock Drilling Dust Control Solutions

In underground mining, dust control is a fundamental issue and regardless of the efficiency of the ventilation system, should be a prerequisite. Dust control systems used in dry rock drilling applications are not only a solution to the OH&S and environmental problems, they also contribute to increased production and productivity. Mining diamonds underground requires special equipment and techniques. Water is normally used for dust control, but when mining in Kimberlite, water is not allowed to be used in the rock drilling process. ILMEG provides dust control systems specially designed for dry rock drilling applications. There are many ILMEG dust control solutions in operation in South Africa today.

Superior Capacity The suction capacity, created by the unique design of the suction fan, is sufficient for any drilling application. The new self-cleaning filters, which are cleaned with reversed air during the drilling process, ensure that the full filter capacity is utilized at all times. Improved efficiency Clean filters combined with a suction fan with high efficiency mean reduced power consumption and less

noise compared to existing dust collectors. Reliable The new filter design, using 2 filters instead of 12 filters in combination with high quality components result in high reliability of the system. Compact and Robust The X-Series is specially designed for the extreme demand of mobile drilling equipment in the construction and mining industry.

ILMEG is developing, producing and selling its own products. “We focus on our customers and their requirements and develop our products especially for their needs� says Magnus Eriksson President ILMEG Products AB. One of the recent innovations of the company is a Dust Collector unit with selfcleaning filters. These are the main features of the new ILMEG Dust Collector:


The Cuttings Collector mounted at the collaring point of the feedbeam is one key to the dust free environment. |July-August 2020 Issue

PAMWE Mining Services support in Southern Africa. During many years PAMWE Mining Services has been our partner in sales and service for the southern Africa region. PAMWE has done a splendid job supporting our customers in Southern Africa. Especially in the underground diamond mining industry. “We focus on our task to support our customers with dust control solutions” Says Abel Mazanhi Ngwenya, Director PAMWE Mining Services. “We have a close link

to ILMEG Products AB in Sweden safeguarding the ability to supply the optimal solutions when it comes to dust control issues in the Construction and Mining Industry” Abel continues. ILMEG Provides dust collector solutions for different rock drilling applications: face drilling, single pass bolting, cable bolting and production drilling. These dust collectors are based on the X-series and are normally rig mounted for best mobility of the equipment.

ILMEG CDC 2000 dust collector collects the cuttings and dust LMEG provides also standalone dust collector solutions, the CDC 2000, collects the drill cuttings and dust into a container. The CDC 2000 is electrically driven can easily be connected to any rock drill.

Leader in dust control solutions for dry drilling applications

Distributed by:

Pamwe Mining Services Unit 3, 7 Dakota Crescent Airport Park Germiston 1401 Tel +27 113832119

| July-August Issue 2020


Think Local – Labote Inco/ Ecotherm Oven & Incubators


idely used for a variety of laboratory and industrial applications in Southern Africa over the last 38 years, the Labotec EcoTherm Oven and IncoTherm Incubator range were recently upgraded. High quality materials, reliability and ease-


of-use are key factors you will find in this range of locally manufactured ovens and incubators from Labotec, enabling you to make the most cost effective choice, with peace of mind that the units have stood the test of time. Visually, you will notice a stainless steel outer body with a powder coated outer door and control panel instead of fully powder coated exterior, and a new ergonomic design

change to both the door and control panel. For better ease of use there is a new slam lock door handle and improved door hinge that prevents the door from opening into the body. Labotec’s EcoTherm ovens will operate in the temperature range of ambient +7°C to 250°C with a choice of 5 different capacities, ideal for drying processes, ageing, |July-August 2020 Issue

curing and general investigations. The Labotec IncoTherm incubators are ideal for use in microbiology and related fields, will operate at temperatures ambient +7°C to 110°C also with a choice of 5 capacities. All Labotec ovens are supplied with a forced draught airflow system. They utilise a maintenance-free fan and motor with homogenous temperature distribution and faster drying times that contributes to their sought after benefits translating into good value for money. | July-August Issue 2020


Air percussion drilling for the Mining Industry


he mining industry and mineral exploration involves drilling to discover subsurface conditions. Over the years, there has been many advances in drilling technologies and techniques in the various sectors; however, in the mining sector there have been no significant advances. Generally, mineral exploration involves percussion and/or rotary drilling to produce rock chips and samples of core for evaluation by the geological team and mining engineers. Drilling is used to obtain detailed subsurface information. This allows the mine to gather sufficient data on mineralogy in the rock formations to resource the mine and have an expected life span. In addition to the mineralogy information gathered, significant geological information is also collected which allows the mining engineers to effectively build the mining model to ensure the safety of the mine and all of its employees and contractors. There are three primary techniques that can be used for mineral exploration. Selecting the appropriate technique will depend on several factors including cost, the environment, type of equipment required, and the skill and knowledge of those involved. We will focus on Reverse Circulation Air Percussion drilling. Reverse circulation drilling is more expensive than rotary air blasting. It also requires more equipment and greater operating skills. Although there is an increase in costs, RC drilling results in greater sample accuracy and recovery, making it a more popular form of mining exploration. It is the most common drilling technique used for mining exploration.

drilling, a dual wall drill rod is utilized. Air is injected between the annulus of the two tubes. The air exits the drill string behind the bit. The air and cuttings are forced across the face of the bit and back up inside of the inner tube which is sealed using O-rings and seated in the outer tube using a circlip. From there, the air and cuttings travel back to the surface out to the top of the rotary head through a deflector elbow along a discharge hose to the cyclone. At the face of the bit, the air is prevented from rising the annulus with a collar or shroud. The rock is fragmented into chips using a piston that delivers rapid impacts to the drill stem, transferring energy to the drill bit. These blows to the rock are delivered by the bit, while a rotational device makes sure that the bit hits a new rock surface with each blow at a rate of 90 rpm. A feed force is applied to maintain rock/bit contact.

Compressed air (950cfm & 24 bar) is used to remove or flush the drill cutting from the hole, advancing the hole depth efficiently. GeoGroup has a fleet of three Super Rock 1000 percussive drills which are used to provide their clients with the various information they may require. These are mounted to Samil 6x6 carriers to ensure any terrain or site conditions can be met with very little difficulty. GeoGroup has worked on various projects around South Africa and Lesotho conducting RC Drilling by assisting clients in obtaining the desired information. These projects have ranged from expansions of existing Zinc, Lead and Copper mines in the Northern Cape to working at the bottom of expansive open cast pits following and delineating kimberlite pipes in Lesotho.

RC drilling is a form of percussion drilling. With RC

16 | July-August Issue 2020 | July-August Issue 2020


Haul Road construction for the Mining Industry The first comprehensive treatise on mining haul road design, construction, operation and management, Mining Haul Roads – Theory and Practice published by Taylor and Francis in 2018 presents an authoritative compendium of worldwide experience and state of the art practices in haul road design, construction, operation and management. The book provides a complete practical reference for mining operations, contractors and mine planners alike, as well as civil engineering practitioners and consulting engineers. The need for updated guidelines was first recognised in the mid 90’s in South Africa where Roger Thompson and Alex Visser from the University of Pretoria, developed updated design techniques for structural (layerworks), functional (wearing course) and maintenance management of mine roads, stemming from research and extensive mine-site application and developmental work supported by industry research partners and clients world-wide. The book is a result of the integration of operational aspects, planning/design and civil engineering applied to mining engineering, combining the areas of expertise of each one of the three authors and represents a key comprehensive update and expansion of mine haul road design guidelines since the USBM publication dating back to the 1970’s.. Further international collaborative work with surface mining operations led to the books’ three authors – Roger Thompson (Mineravia Consulting – Australia), Alex Visser (University of Pretoria, South Africa) and Rodrigo Peroni (Federal University of Rio Grande do Sul, Brazil) working together to capture mine road design and management practices developed and applied over the last 25 years by the three authors, over three continents and many of

the world’s leading surface mining operations. In this book, the authors: •

Introduce the four design components of an integrated design methodology for mining haul roads – geometric (including drainage), structural, functional and maintenance management Illustrate how mine planning constraints inform road design requirements Develop the analytical framework for each of the design components from their theoretical basis, and using typical mine-site applications, illustrate how site-specific design guidelines are developed, together with their practical implementation

construction project based on the design methodologies previously introduced -List and describe future trends in mine haulage system development, how mining haul road design will evolve to meet these new system challenges and how the increasing availability of data is used to manage road performance and ultimately provide 24x7 trafficability.

Jim Humphreys, Professional Engineer, AHS developer for a major North American truck manufacturer and Distinguished Member of the Society of Mining, Metallurgy and Exploration (USA) describes the book as. “ the most definitive treatise on mining haul roads ever written….. There has never been a text that addresses the many facets of mining haul roads on such a scope….” The book was also awarded the ‘Outstanding Professional Title in Engineering’ by the Informa Group in 2018 and is testament to support received from mine sites and staff whose efforts to understand and improve the performance of mine haul roads contributed to the many practical aspects of the book.

“the most definitive treatise on mining haul roads ever written….. There has never been a text that addresses the many facets of mining haul roads on such a scope….”


Summarise the key road safety and geometric design considerations specific to mine haul roads Specify the mechanistic structural design approach unique to ultraheavy wheel loading associated with OTR mine trucks Describe the selection, application and management of the road wearing course material, together with its rehabilitation, including the use of palliatives Develop road and operating cost models for estimating total road-user costs , based on road rolling resistance measurement and modelling techniques Illustrate the approach of costing a mining road

Author: Roger Thompson, Mineravia Consulting ( Email

Contacts: Alex Visser (South Africa)

Rodrigo Peroni (Brazil)

Roger Thompson (Australasia) | July-August Issue 2020


MINING Rooted in Mining.




Superior SoilStabilization



Superior Dust Control

Superior Soil Stabilisation



DUST| STOP®‘sprimary use is to provide an environmentally friendly alternative for dust control on roads and unpaved surfaces of almost any kind. Additionally, the DUST| STOP® line of products offers an excellent solution for dust and erosion control of tailings and stockpiles of a variety of material types.

EARTHZYME® A long-term soil stabilizer that is designedto increase stability of high clay content materials, EARTHZYME® is used to strengthen the treated material by increasing its density after compaction.

Unlike many alternatives, DUST| STOP® contains no chlorides, hydrocarbonsor toxic by-products, so it is neither corrosive to vehicles, toxic to roadside vegetation, nor harmful to use around nearby water bodies or environmentally sensitive areas.

As a result of the increased density, treated materials exhibit excellent improvements in CBR values (California Bearing Ratio) and reduced swelling potential, therefore a more durable road surface during wet and dry weather.



- Reduces operational costs of managing roads through less watering and grading frequency - Improved productivity by eliminating dust allowing faster speeds - Helps repel water and increase strength - Requires less frequency re-application than traditional chloride,bitumen based products and water - Non- corrosive, non- toxic and environmental friendly - Applicable with standard equipment, allowing for easy adoption

- Long term reduction in maintenance requirements and cost - Decrease fuel consumption of haul trucks using the road due to decreased rolling resistance - Reduced permeability allowing for a harder, more durable soil in wet weather


EARTHZYME® is not a glue-it acts on the clay component already in the road materials. Comprising of a combination of enzymes, electrolytes and surfactants, it works by releasing water from the soil, enabling it to be compacted to a denser form and it then manipulates the clay to bind it together permanently, increasing its strength and density.

Through a single application of EARTHZYME®, significant cost savings result through the use of cheaper road building materials, long term reductions in maintenance costs and vastly reduced rolling resistance. Reductionsin dust are also a pleasant side-effect.





Superior Dust Control.

Superior SoilStabilization.


8.8% 61%











ASREPORTED BY:Syncrude Canada







Cypher'sproducts comply with BoeingD6-17487Conformity, therefore are non-corrosive to airplanes andany other vehicles or equipment usingtreated runwaysor roads.


Product of

MINING Rooted in Mining. Rustenburg Office (Head Office) 36 Bult Street Rustenburg, 0299 Tel: +27 (0)14 592 1560 Fax: +27 (0)86 547 3593 Email:

Klerksdorp Office 06 Mahogany Avenue Industria Klerksdorp, 2570 Tel: +27 (0)18 462 0872 Fax: +27 (0)86 547 3593 Email:

Middelburg Office Block D3, Office No. 18 02 Walter Sisulu Street Midlands Office Park Middelburg, 1050 Tel: +27 (0)13 007 1359 Fax: +27 (0)86 547 3593 Email:

Equipment for effective demolition: Demolition in mining Demolitions take place in mines during upgrades or at the end-oflife of a mine. In the case of a mine that has come to the end of its useful life, environmental aspects need to be taken into consideration to incorporate cleanup and reclamation of the sites. These decisions can affect the schedule and cost of the demolition activities because they may control how the demolition contractor will conduct his activities. In the case of demolitions to upgrade facilities, the fact that it is a live site means that extra care and safety must be taken in order not to disrupt mining activities on the site both underground and above ground. When sourcing for a demolition contractor, experience and track record should be key. Assess the qualifications of the personnel and peruse their past projects. Determine its suitability for your particular project because each project always has unique challenges. Even while the contractor may tout himself as the best in the market ask for a list of references of satisfied customers. When it comes to the type of equipment, we take a look at some of the companies and what they have to offer. BREAKER TECHNOLOGY BTI manufactures and distributes a wide range of mine, quarry, construction and demolition equipment. Specializing in hydraulic hammers, mobile rock breakers, stationary and portable rock breaker systems, construction and demolition attachments, BTI is also well recognized for their full line of underground utility vehicles

including mobile scalers, scissors lifts, crane trucks, lube trucks, anfo loaders, shotcrete mixers and placers, cassette systems and personnel vehicles. Applications range from primary and secondary sites involved in construction, demolition or recycling, to quarries and underground mining operations such as scaling and explosives loading. Technology plays a critical role in the company’s continued successes. BTI enjoys a reputation for engineering products with the most advanced technologies available, yet the resulting systems are remarkably easy to use. Its breaker systems, for example, literally have benchmarked reliability and performance across a broad range of applications. Similarly, its hydraulic breakers use sophisticated technology to produce a simple design. With only two internal moving parts, this line of breakers and attachments makes the operation of hydraulic equipment easy, flexible and reliable. Field-proven and customer-sanctioned, BTI products are enthusiastically accepted as the standard for the industries they serve. For the larger stationary crushing plants, BTI has designed and developed TTX Series Rock breaker System. This system is used in applications where extremely hard rock is present or a large coverage area is required. It can be used for material handling applications. Systems can be equipped with a 4,000 to 10,000 ft-lb class breaker, models available with up to 45 ft Nom. Horizontal Reach (with breaker vertical).Features and benefits of TTX series rock breaker system include: high strength steel (bent, 4-plate) construction 65 ksi | July-August Issue 2020

tensile strength; 50 ksi yield strength for longer service life, reinforced pivot and mounting pin joints from improved durability, hardened steel bushings in pivot joints and larger diameter pivot pins provide reduced bearing pressure and increased service life, thick pedestal base plate – 2.0” (50 mm) for stable mounting – optional concrete installation available, sealed turn-table bearing and gear drive for longer service life, increased cross-sectional strength of boom and dipper where high stress is realized and can-bus (iqan) control technology for more precise control and ramping for improved operation response. BTI’s Low Profile Mobile Breaker Systems eliminate disruptive, costly and unsafe blasting in stopes, draw points and grizzlies, providing efficient, safer alternatives to secondary blasting.


Morningstar solar controllers for protecting oil & gas operations and making mining operations safer


The fossil-fuel industry, particularly oil and gas, depends on the renewable energy industry for many aspects of extraction, production and transportation. Pumping and mining operations are often far removed from access to the electrical grid, and using generators is often prohibitively expensive and impractical. At the well, renewables are called upon to power injection pumps, lighting equipment, and monitoring devices. Along the pipeline, renewables are often the only means of providing cathodic protection to prevent corrosion and ensure pipeline integrity. Renewable energy provides costeffective, dependable electricity for mission-critical communications, data acquisition, metering, site security, and much more.

typically via satellite or other wireless communications.

Cathodic protection is primarily used to protect steel structures buried in soil or immersed in water and offers many advantages for corrosion protection. Electronic cathodic protection must maintain constant voltage and current to be effective. Therefore, it is important for these sites to maintain good charging control and communications

The “heart and brains” of these solar electric systems is its solar controller. The solar controller provides proper battery charging, which will fully charge the batteries during the day while also protecting the battery, often the most expensive component, from overcharging. By controlling the PV/solar-generated DC electricity flowing from the panels, or modules, into

In mining, many of the same conditions apply. Far removed from grid electricity, mines require on-site electrical generation for critical safety systems and security systems. Often this electrical demand is on top of the already high power-consumption of an operating mine, which also has to take heavy mining, transportation and ventilation equipment into account. Solar electric-powered lighting towers are increasingly used to provide power generation for dispatch, data networks, data and lighting. For on-site lighting, mining operations often use mobile light trailer towers with high efficiency LED spotlights powered by batteries recharged with solar panels and sometimes a wind turbine-powered generator.

batteries for storage as well as sending on to run connected loads, the controller both manages the delivery and quality of the solar-produced electricity and maintains battery health. These controllers must operate in extreme high or low temperatures. Morningstar’s SunSaver, ProStar and TriStar families of solar controllers have all been used with off-grid cathodic protection systems. Higher power systems may utilize multiple TriStar or TriStar MPPT controllers in parallel to charge the battery bank. Cathodic protection and lighting load control can include products from other manufacturers to provide constant voltage and/or constant current. These power supplies therefore can include DC-DC load control which may cause high current surges at times. Therefore, it is important to consider carefully whether Morningstar’s load control circuit can handle the type of surge capability for these loads. If the load current capability cannot meet the inrush current requirement for the load, Morningstar offers a Relay Driver to activate higher rated relays for LVD load control. | July-August Issue 2020

Communications for these sites to monitor not only the solar controller data but also the equipment data is critical. If the system shuts down, immediate intervention can prevent losses, downtime and damage. Morningstar offers both serial and Ethernet communications using industry standard MODBUS™ protocol with many different solar controllers including the ProStar and TriStar families as well as the Relay Driver. These systems often include an RTU with a MODBUS™ interface which is controlled and monitored by a central SCADA system. The RTU equipment at these sights will all be powered by the solar controllers which makes it even more critical to maintain power at these remote sites. Selected Morningstar components are now also SNMP-compatible (Simple Network Management Protocol), an internet standard protocol that is used to

manage and monitor devices on an IP network. SNMP is used in industrial applications within an existing network infrastructure, as an easy way to gather data from and accurately monitor network equipment assets on site. SNMP allows for a simple and convenient way to view and modify the status of critical system components on a private Local Area Network (LAN) or across a WAN (Wide Area Network) if so desired. Morningstar’s SNMP-enabled Ethernet MeterBus Converter EMC-1 provides this capability.

For this reason Morningstar has the industry’s broadest line of fanless charge controllers, including models that meet all US and International requirements for hazardous locations. The superior ‘fanless’ thermal design means no fans to fail, waste electricity, or shorten the life of the controller by blowing in dirt and debris. Both the SunSaver and SunKeeper charge controllers are approved for hazardous locations, meeting Class 1/ Division 2 Groups A-D requirements, and are ideal for use in oil & gas operations.

Morningstar solar controllers offer unmatched reliability; reducing or even eliminating field-failure and downtime, and the need for difficult and costly replacements in remote locations. Because charge controllers handle high voltages they produce heat, which means thermal management is essential to prolonging system life. | July-August Issue 2020


Solving the challenges of mining communications Modern mine operators are increasingly recognizing the need for technologically advanced communication systems for both worker safety and operational efficiency. Keeping workers connected and informed is key to a safe and efficient workplace and communications play a vital role in ensuring operational coordination. We have asked Regional Director Carsten Laursen and Regional Sales Director Stuart Will from DAMM Cellular Systems how their communication solutions conform to these requirements. Fail-safe voice and data communications Why should mining companies consider a DAMM radio communication solution? “DAMM fully understands the critical importance of fail-safe voice and data communications. We specialise in providing equipment perfectly suited to the remote, harsh environments and severe working conditions of mining operations. Our solutions provide crucial communications integration between the mining site, rail and port operations and centralised administration, enhancing both efficiency and the safety of personnel,” says Carsten. When communication systems fail, mining companies have to stop operations, which costs millions a day. The decentralized architecture of the DAMM system combined with a fully redundant setup prevent downtime, even if the network is hit by lightning. Along with high availability, DAMM’s system includes a wide range of other safety-enhancing features, including clear voice quality even in noisy environments, emergency calls, man-down functionality, geo-location services, multiple pre-emptive calls, broadcast messaging alerts and direct alarm dispatch to emergency units.

Easy to deploy, move and maintain How are DAMM’s products specifically useful for the mining sector? “Our IP65-protected outdoor base stations are built for remote areas, harsh environments from high heat and dust to rain and low temperatures. Their compact design and low weight make them easy to mount directly in masts, providing coverage for the entire mining site. In addition, their design makes them suitable for portable deployment, e.g. on trailers that can be moved to adapt to changing mining locations or along haul roads. Thanks to the simple and self-configuring setup, you can quickly and seamlessly expand your system when needed,” Stuart explains. Breakthrough TCO and proven success What makes DAMM’s products especially suitable for the African region? “Not only are our products built for harsh environments and for improving operational efficiency and safety. We are committed to offering solutions that ensure low CAPEX and OPEX. One of the key features of our outdoor base stations is their cost efficiency. The low power consumption saves on electricity costs and even allows a completely solar-powered solution providing portability saving costs every day. In addition, the base stations are designed with passive cooling, which means there is no additional cooling systems requiring a power source, maintenance, or repair – indeed low maintenance is a key trait of our products. Our system is not only cost-efficient when it comes to purchasing and operating it. Due to the high reliability, you are also guaranteed a minimum of costly downtime with operations coming to a standstill,” says Carsten. Stuart adds, “We have many years of experience in providing costeffective solutions to major players within the mining industry around


the world and have delivered systems for huge operations run by Rio Tinto, BHP, Glencore and Fortescue Metals Group (Australia), New Gold (Canada) and BUMA (Indonesia) to name but a few. We therefore have the know-how and the expertise needed to support similar large-scale operations in Africa.” About DAMM With its nearly 40 years in the industry, DAMM is a well-established name within TETRA radio communication and has built up extensive experience in delivering products that can endure the harsh environments that characterise the mining industry. DAMM’s TetraFlex® solution is 100% IP-based and comes with complete outdoor and/or indoor base stations and comprehensive features as well as integrated software such as network management, voice and data recording and full dispatch applications. To learn more about our products and solutions and how we can help you, please contact:

Carsten Laursen Regional Director

Stuart Will Regional Sales Director | July-August Issue 2020

FAIL-SAFE VOICE & DATA COMMUNICATIONS Increase worker’s safety and operational efficiency with 100% IP-based digital radio infrastructure systems from DAMM. DAMM products are designed for operation directly in harsh environments, and provides the most reliable, cost-efficient and user-friendly solution for digital voice and data communications for the mining industry.


Trusted by industry leaders worldwide DAMM solutions have been deployed for a wide range of projects within mining, including: Rio Tinto • New Gold • BUMA Fortesque Metal Group • BHP

Cap Lamp With Integrated Missing Person Locator Miners now can be found even through solid rock-walls. It is possible thanks to a 2 in 1 device SmartLight-05/M1. It consists of a LED Cap Lamp with an integrated Missing Person Locator (MPL). The MPL sends a low frequency signal that penetrates the rocks. It is received and processed by the latest technology receiver device called MinSearch-15. Rescue teams use this device to locate users of SmartLight05/M1. It is possible to locate a miner within 30m in sphere, even through solid rock-walls. The signal lasts for up to a week, from the full battery charge of SmartLight-05/M1. To assist the rescue teams, PJ Tech designed an app that allows to download the list of missing/ trapped miners prior to the commencement of the rescue action.

Due to the success as well as realisation of the benefits Mine Rescue Services issued a positive product evaluation report.

Additional advantages:

SmartLight-05/M1 is fully approved by SABS according to their latest SANS-1438:2013 standard. In addition the receiver MinSearch-15 has the required ATEX certification. Interestingly, SANS-1438 standard is the stringiest in the world.

Other cap lamp manufacturers can use PJ Tech’s MPL too as it is also available in a standalone version. It only requires to be placed under their cap lamp cover and electrical connection of its 2 wires.

• • •

5 LEDs (in Head Light: 1 off Main & 3 off additional and in Battery Cover: 1 off Emergency) 1000 battery charges guaranteed Vertical head lamp adjustment RFID tag ready Cap Lamp Management Software

PJ Tech’s has also developed a very handy tool. Their Cap Lamp Management Software allows lamp room Supervisor to monitor the SmartLights. It also allows for Management reporting, maintenance planning, etc. Since it is a web based software, it can be viewed by any device with an internet browser.

This is a significant safety improvement as the rescue duration can drastically be shortened.

As a result tragedies can be avoided and miners’ lives saved. PJ Tech, a South African manufacturer of these devices, performed multiple tests with Mine Rescue Services. The tests took place at Mine Rescue Services training centre, as well as in real mining environment.

28 | July-August Issue 2020




Jan-March 2020

Protective clothing a must in mining

There are a number of potential hazards and risks to employees’ safety while working on mining and manufacturing worksites. It’s then essential for employees to wear the correct safety equipment and follow the necessary safety protocols to protect their health.

Barrier to the elements: Employees are often required to work in extreme conditions such as rain, high winds, freezing cold and extreme heat. Protective clothing will help to prevent conditions such as frostbite, sunburn or wind burn.

Organisations must also ensure anyone visiting the workplace wears the appropriate protective equipment where necessary. It’s then essential to inform any visitors of safety procedures and alert them to potential hazards. Maintain equipment

Types of equipment If an accident occurs an employee wearing the right personal protective clothing can reduce their risk of injuries such as broken bones, minor burns, rashes or cuts. Employers must provide personal protective equipment to workers at the workplace. It’s then important for employers and employees to understand the benefits of protective clothing and how to use it correctly. Here are some reasons why protective clothing and equipment is important: Get noticed: Employees wearing high visibility gear are much more likely to be seen by other people. This is especially important if employees are working near machinery or a road where they are at risk of being hit by a vehicle. Protect their skin: Protective clothing is specifically designed to protect employees’ skin from cuts, grazes or rashes from hazardous chemicals. Some clothing is also fire resistant and can prevent minor burns.


The types of protective equipment used in the mining and manufacturing industries includes safety goggles, steeltoed boots, safety helmets, long-sleeved shirts, long trousers, high visibility vests, ear plugs or hats. It’s also important to have speciality protective clothing and equipment for specific jobs such as welding helmets or arc flash face shields. It’s the employer’s duty to ensure clothing and equipment is appropriately fitting for each employee. For example, if a respirator is too large or too small it will not prevent employees from breathing in harmful substances. Clothing and equipment may need to be purchased for each individual employee. Train employees Businesses are required to train their employees on the appropriate way to wear protective equipment and how to use it correctly. They should also be instructed on how to store equipment correctly to ensure it remains in good working order.

The regulations state that it’s the business’ responsibility to ensure all protective clothing and equipment is functional and regularly maintained. This involves replacing damaged or faulty equipment immediately. Employees also have a duty to report damaged equipment and to ensure clothing is cleaned and stored correctly. Where to buy clothing It’s important to purchase the right personal protective clothing for each specific situation to protect employees health and safety. There are a number of different options available to choose from, which can make it difficult to purchase the right equipment. It’s a good idea to use an industry supplier, who has a wide range of personal protective equipment specially designed for the mining and manufacturing industries. Wearing protective clothing won’t stop accidents from occurring but it can greatly reduce the risk of injuries and health problems. Protective clothing should be combined with strict safety procedures and regular training to protect employee health and safety. | July-August Issue 2020



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Jan-March 2020

LIBS chemical sensing applications in the mining and minerals industry

Figure 1 Example of rock surface scan displaying Copper concentration Spectral Industries B.V., Delft, The Netherlands The mining industry is faced with an increasing scarcity of natural resources. At the same time, the global demand for resources keeps growing and the requirement to reduce the environmental footprint of mining becomes more important. This creates the need to develop innovative solutions that increase the efficiency and sustainability of mining natural resources. Mining operations deal with huge quantities of excavated material with varying mineral concentrations and economic value. Increased knowledge about the composition of this material provides opportunities to improve decision making for stockpiling, sorting, and mineral processing. However, no systems currently exist that can be used to measure the chemical composition of large material quantities in real-time. LIBS chemical sensor technology provides a solution, because no sample preparation is required and measurements can be performed at relatively high speeds. At SPECTRAL Industries we work together with the mining industry to develop LIBS-based sensor applications for the mining environment. Examples of applications are in-line conveyor belt analysis, scanning exposed rock surfaces (see Figure 1) and


Figure 2 Example of part of the output of a drill core scan (warmer colors are higher concentrations)

scanning drill chips from blasthole drilling. Additionally, we also work on applications that improve the exploration for new mineral deposits such as the scanning of drill cores (see Figure 2). We develop the best LIBS sensor for a specific application using our indepth expertise of lasers, spectrometers and data processing One of the major challenges of using LIBS for characterizing the mineral quantity in rocks is the heterogeneity of this material. Rocks are composed of many different minerals with various grain sizes. Each mineral consists of several different elements and for some minerals the relative quantity of these elements can vary. Depending on the size of the mineral grains, a single LIBS measurement can represent one or several minerals. Development of advanced data processing techniques is therefore required in order to provide quantitative compositional information that meets the required accuracy. Additionally, calibrations need to be tailored to the geological setting of a specific mineral deposit to take all the variation between rock types and mineralogy into account. The results obtained using LIBS chemical sensing on ore samples from active mining operations show that LIBS can be used to provide the information that is needed to improve the efficiency and sustainability of future mining.

SPECTRAL Industries is a new chemical sensor developer and manufacturer, with a focus on applications in the mining and minerals industry. SPECTRAL’s chemical sensors are robust, mobile & fast: they can be applied on (fast) moving raw material. The sensor features our unique IRIS spectrometer with world-class signal-to-noise (S/N) ratio, rugged pulse laser source and highly efficient optics. The design allows for flexible integration into industrial equipment and can be mounted in any orientation. Suitable for a wide range of environmental conditions, it offers low maintenance cost and improves processes by delivering real-time information. SPECTRAL delivers its unique sensor systems for the following applications: • • • • •

Drill core scanning Rock surface mapping Drill cuttings analysis Ore, concentrate and slag characterization Muck pile characterization

The LIBX sensor can be applied for automated ore sorting, that separates valuable from nonvaluable rocks to prevent unnecessary cost for processing worthless ore and maximize return on investment. The technology is highly scalable as the hardware is suitable for any type of ore and materials. | July-August Issue 2020

Innovate your mining business with real-�me chemical sensing LIBS chemical sensing for mining & minerals Knowledge about the composi�on of your raw materials provides opportuni�es to improve efficiency. SPECTRAL co-operates with mining companies to develop LIBS sensors that provide this knowledge. The advantage of our LIBS sensor is that it can determine the full elemental composition of any type of material stream 24/7 without the need for taking samples. The LIBS sensor can also be applied directly in the mine or during exploration without having to ship samples to the lab. Examples of products that SPECTRAL is working on:

Drill core

Mine face

Conveyor belt SPECTRAL develops and manufactures customized LIBS sensors systems to measure the concentra�on of the elements of interest. We apply the op�mal hardware/so�ware combina�on to produce a low cost / robust sensor system that meets the requirements. SPECTRAL delivers complete sensing solutions

For more informa�on: Ad Maas, PhD phone: +316 2280 7946

Oren : The Digital mining platform of choice


hell and IBM have recently launched Oren, a global B2B Digital mining services marketplace platform, codeveloped by the companies aimed at helping mining companies find solutions related to safety, sustainability, mine planning and operational efficiency. By hosting new technology and digital solutions in one place, Oren aims to accelerate the digitisation of the mining industry, speed up the transformation of mining workflows and build in more operational resiliency in a rapidly changing world. As current world events disrupt regular business operations, mining companies are looking to become more agile and resilient by embedding more automated mine solutions such as self-driving haul trucks and remote operations centres in their operations. To do this, mining operations need to quickly become more digital and intelligent at every step, both within the mines and throughout the wider value chains. The Oren marketplace platform allows solution developers – both established enterprise companies as well as start-ups - to get their market innovations to mining clients quickly. Mining companies may not always have the time and budgets to invest in developing


their own new tools to meet these challenges. They are looking to deploy ready-made, proven solutions to improve operations by aggregating data from different sources to create a single view of their operations in order to abstract insights and really drive action and make more informed, data driven decisions. Oren also aims to enable mining operations to develop a roadmap designed to deliver the interconnected mine of the future by creating connected solutions that integrate and leverage data, artificial intelligence, Internet of Things, automation and analytics. This can give miners not only access to digital mining services but also bring solutions and services that can enable miners to imagine and build up intelligent workflows that integrate all services across the mining ecosystem. The Oren team will bring expert support to mining companies to help build their specific digital journey roadmap while the B2B marketplace provides solutions to get things done, including: Tailored search This allows users to identify the most appropriate solutions by customising their search parameters in relation to their responsibilities, the business challenge they are tackling or the nature of the technical solution they are seeking. Access to field-proven mining solutions

This includes: • MachineMax, a cloudbased digital service for off-highway vehicles and industrials fleet optimisation. • Shell Remote Sense, a smart lubricant condition monitoring service delivering insights for industrial companies to optimise equipment health, lower maintenance costs and increase operational efficiency. • IBM's Maintenance, Repair and Operations Inventory Optimisation Services which helps manage spare parts inventory optimally for both critical and noncritical spares. Dedicated environmental management and compliance software The software can provide detailed analysis and reporting on pollutant inventories, greenhouse gas emission, energy consumption, environmental impact assessment, mine rehabilitation and mine life cycle assessment. It is anticipated that one third of the solutions available on the marketplace will be related to sustainability with solutions on Oren from both large enterprise and start-ups such as Hydrox Holdings, which developed a technology to unlock inexpensive hydrogen production as a renewable energy source. | July-August Issue 2020

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Pg.02 South African Mining & Engineering Supplies Pg. 07 Novaflex Pg. 11 Delta Hydraulics Pg. 13 Pamwe Mining Pg. 17 Geogroup Pg. 20-22 Modi Mining Pg.27 Damm Cellular Pg.29 Shamba Lodge Pg30 Karmord Pg.33 Knight Safety Gear Pg.35 Spectral Industries Pg.37 Agruline Pg.38 Faiztech Pg.39 Eriez FLoatation Pg.40 Deep Sea Elecetronics | May-June Issue 2020

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DSEControl® M-Series DSE has been delivering world-class control solutions to its customers for over 45 years. During this time the company has developed a reputation across the globe for its UK engineering and manufacturing excellence. The DSE M-Series builds on this reputation. The innovative collection of programmable controllers & displays and CAN slave modules provide customers with complete mining control solutions. To learn more about DSE M-Series products, visit

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