Quarrying Africa Issue May/June 2022

MAY/JUNE 2022

MAY/JUNE 2022

PREMIER INFORMATION HUB FOR THE SUB-SAHARAN AFRICAN QUARRYING SECTOR

PREMIER INFORMATION HUB FOR THE SUB-SAHARAN AFRICAN QUARRYING SECTOR

DRIVING SCANIA’S

CUSTOMER-CENTRIC APPROACH

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Winning the cost control battle

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A new era of quarrying efficiency

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Optimising loadout processes

VOL. 1 ISSUE 3

COMMENT

IS MANUFACTURED SAND THE MATERIAL OF THE FUTURE?

MUNESU SHOKO Publishing Editor Email: munesu@quarryingafrica.com

LinkedIn: Munesu Shoko

Quarrying Africa

THE nomadic nature of my job takes me to different quarry operations around South Africa and the region at large.

The overarching observation from my recent visits is the growing demand for manufactured sand.

Sand has traditionally been obtained from natural sources such as rivers and coastlines. However, new regulations have been enacted to protect these sources. In many cases, sourcing sand from riverbanks and shorelines has been outlawed completely because of the dire environmental consequences such as erosion in rivers and coastlines, as well as changes in the water’s PH levels.

That sand is one of the most important materials in the modern world is no overstatement. In fact, it is the second largest natural resource by volume after water and accounts for the largest volume of solid material extracted globally.

Yet, according to some forecasts, buildable sand may run out as early as the first half of this century. This is a worrying reality because sand and gravel build the foundations of our economies, finding use in not only construction, but other diverse sectors from electronics to glass.

A recent United Nations report notes that demand for sand resources is rising.

Shifting consumption patterns, growing populations, increasing urbanisation and infrastructure development have increased demand three-fold over the last two decades. The world now needs 50-billion tonnes per year, an average of 18 kg per person per day.

The challenge is that the world has been exceeding easily available sand resources at a growing rate for decades. We are spending our sand ‘budget’ faster than we can produce responsibly. The increasing discrepancy between the need for aggregates in society and the scarcity of natural sand (the result of exhaustion of resources and environmental considerations), has urged the industry to look for a suitable and sustainable alternative fine aggregate. Manufactured sand has therefore proven to be the most

economical and ecological alternative.

Forward-thinking aggregate producers are therefore positioning themselves to make the most of this projected demand for manufactured sand, with investments in new sand production technologies taking centre stage across several operations. In recent years, sustainable technologies that produce well-shaped, washed and graded manufactured sand have also come to market to help the migration from natural sand.

For end users, the benefits of taking the manufactured sand route abound.

Manufactured sand generally has higher compressive and flexural strength than natural sand. Due to weathering, natural sand particles are rounded, whereas manufactured sand particles are angular and have a rougher surface texture, allowing better bonding with the mortar in concrete, thereby providing improved strength properties.

Manufactured sand has also been proven to offer better workability. It is graded with precision and consistency thus has higher fineness modulus compared to natural sand and crusher dust. This gives good workability for concrete and masonry.

In addition, manufactured sand is free of impurities such as clay, dust and silt and has denser particle packing than natural sand particles, thereby reducing the voids in aggregate and hence saving cement requirement in concrete production.

The depletion of natural sand resources is a major concern, and in areas where demand is high, there are fewer and fewer sustainable sources.

As a result, sand has to be transported over greater distances which has led to price increases. Manufactured sand can be produced close to construction sites, thus bringing down transportation costs and enabling consistent supply.

The future of the aggregates market is manufactured sand. Sand is a key ingredient in concrete, cement and asphalt. As cities around the world continue to grow, the demand for sand will grow at an exponential rate. a

May/June 2022 | Vol. 1 Issue 3 | www.quarryingafrica.com |

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CONTENTS 22

12

28 18

Environmental Audits resume

04

Holcim to sell majority stake in Lafarge Zimbabwe

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INDUSTRY NEWS

04

Afrimat Construction Index shows construction decline in Q1 Illegal mining poses a major threat to mines and quarries AfriSam’s composite cements lead in sustainability drive

| January-February 2022 | Vol. 1 Issue 3 | www.quarryingafrica.com

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LEAD STORY

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DRIVING SCANIA’S CUSTOMER-CENTRIC APPROACH

Publishing Editor: Munesu Shoko Admin: Linda T. Chisi Sub Editor: Glynnis Koch Design: Kudzo Mzire Maputire Web Manager: Thina Bhebhe

Quarrying Africa is a premier information hub for the subSaharan African quarrying sector. It is a valued reference tool positioned as a must-read for the broader spectrum of the aggregates value chain, from quarry operators and aggregate retailers, to concrete and cement producers, mining contractors, aggregate haulage companies and the supply chain at large.

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© Quarrying Africa Quarrying Africa, published by DueNorth Media Africa, makes constant effort to ensure that content is accurate before publication. The views expressed in the articles reflect the source(s) opinions and are not necessarily the views of the publisher and editor.

The opinions, beliefs and viewpoints expressed by the various thought leaders and contributors do not necessarily reflect the opinions, beliefs and viewpoints of the Quarrying Africa team.

Quarrying Africa prides itself on the educational content published via www.quarryingafrica.com and in Quarrying Africa magazine in print. We believe knowledge is power, which is why we strive to cover topics that affect the quarrying value chain at large.

When size matters

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The economics of workplace safety

50

First ever Liebherr TA 230 ADT in Africa

52 53

SUPPLY CHAIN NEWS

40

Blasting’s role in making mining more sustainable

Printed by:

Contact Information Email: munesu@quarryingafrica.com Cell: +27 (0)73 052 4335

Kwatani casts the spotlight on innovation and digitalisation

May/June 2022 | Vol. 1 Issue 3 | www.quarryingafrica.com |

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INDUSTRY NEWS

Environmental Audits resume

Afrimat delivers robust results as construction materials rebound

The audit is designed to help mines and quarries meet their Environmental and Social Governance (ESG) targets.

The ASPASA Environmental audit programme is now well underway after a two-year Covid-19- influenced break, reports Quarrying Africa. The audit is designed to help mines and quarries meet their Environmental and Social Governance (ESG) targets.

“ESG compliance has become an important component of the modern business environment and is high on the agenda of most organisations, both local and international.

Sustainable mining is critical to the continued existence of the smallscale mining industry whether it be aggregates, sand, dimension stone, clay, salt or any other commodity that is mined in the sector,” says Nico

Pienaar, director of ASPASA. The audit comprises Online and Physical components, both of which are designed to establish the level of compliance and to assist the various operators and managers to improve their knowledge of environmental issues and the compliance requirements.

“Judging from the completed audits to date, the Environmental Audit has been well received by the various managers and their respective teams. All the participating operations have demonstrated a high level of commitment to the process, and they have all presented well prepared documentation to the auditor, for which ASPASA is very grateful,” says Pienaar. a

Afrimat released full year results for the year ended 28 February 2022, with revenue up 26,7% to R4,7-billion (2021: R3,7-billion).

The Bulk Commodities segment, consisting of the Demaneng and Jenkins iron ore mines, as well as the Nkomati anthracite mine, benefited from the successful turnaround of Nkomati and favourable iron ore pricing. The segment contributed 74% to the group’s operating profit.

The Industrial Minerals business delivered returns comparable to preCovid-19 volumes across all regions, delivering an increase in operating profit of 70,2% from R55,5-million to R94,4-million. The acquisition of the feed lime business (Agri Lime) strengthened Afrimat’s footprint in the agricultural lime market in support of deeper diversification in this segment.

Similarly, the Construction Materials segment experienced a return to pre-Covid-19 volumes, resulting in a significant improvement in operating profit of 83,5% from R104,9-million to R192,5-million in the year under review. a

Holcim to sell majority stake in Lafarge Zimbabwe As part of its global divestment strategy, the Holcim Group, through its subsidiary Associated International Cement, is selling its 76,45% stake in Lafarge Zimbabwe to Fossil Mining. The Lafarge Zimbabwe deal follows similar recent divestments in ACC Ltd and Ambuja Cements in India.

In a statement dated 6 June 2022, Lafarge Zimbabwe said: “Further to the cautionary announcement dated 31 May 2022, shareholders and members of the investing public are advised that Associated International Cement Limited, a member of the Holcim group, has entered into a binding agreement for the sale of its 76,45% stake in Lafarge Cement Zimbabwe Limited to Fossil Mines (Private) Limited.

“The transaction, if successfully concluded, may have a material effect on the company’s securities. Accordingly, shareholders and members of the investing public are advised to exercise caution when dealing in the company’s securities until a full announcement is made,” the company said.

Fossil Mining, part of the Fossil Group, owned by Zimbabwean businessman Obey Chimuka, beat competition from Chinese bidder, Huaxin Cement. Having already bought 75% of Lafarge Zambia for US$150-million and concluded a US$10-million deal to acquire Pan African Cement from Lafarge Malawi late last year, the Chinese investor was tipped to win the race to acquire Lafarge Zimbabwe. a

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76,45% Associated International Cement Limited, a member of the Holcim group, has entered into a binding agreement for the sale of its 76,45% stake in Lafarge Cement Zimbabwe Limited to Fossil Mines

Lafarge Zimbabwe is one of the biggest cement manufacturers in Zimbabwe.

| May/June 2022 | Vol. 1 Issue 3 | www.quarryingafrica.com

Afrimat Construction Index shows construction decline in Q1 While many sectors of the economy of have fully recovered from the effects of the Covid-19 pandemic and the subsequent lockdowns, construction activity remains subdued, the latest Afrimat Construction Index finds.

Afrimat, the JSE-listed open pit mining company providing industrial minerals, bulk commodities and construction materials, has released the findings of the Afrimat Construction Index (ACI) for the first quarter of 2022. The ACI is a composite index of the level of activity within the building and construction sectors and is compiled by economist Dr Roelof Botha on behalf of Afrimat.

According to Dr Botha, the lifting of most of the lockdown regulations resulted in a V-shaped recovery for most key sectors of the economy during the second half of 2020, including construction. Since then, several sectors have fully recovered and progressed to a new phase of expansion, but construction sector activity remains subdued.

Although the ACI managed to marginally outperform the gross domestic product (GDP) growth rate during the first quarter of 2022 on a year-on-year basis, the index has returned to its traditional trend of recording a decline between each year’s fourth quarter and the first three months of the following year, recording a drop of 3,5% in the index value (from 118,8 to 114,7).

The only sub-indicator of the ACI that recorded positive growth between the fourth quarter of last year and the first quarter of 2022 was the value of wholesale sales of construction and building materials.

However, compared to the first quarter of last year, the picture is considerably more positive, with four of the nine sub-indicators recording positive growth, whilst two others were virtually unchanged (declines of less than 1%).

“Ever since the ACI recorded its highest level yet, namely 143,8 during the third quarter of 2016, a combination of high interest rates,

Illegal mining poses a major threat to mines and quarries

llegal mining is a growing trend in South Africa.

Andries van Heerden, CEO of Afrimat.

low economic growth, state capture, public sector incompetence and high levels of violent crime have dampened activity in the country’s construction sector,” says Botha.

Compared to the first quarter of 2021, the shining stars of the latest ACI were the volume of building materials produced, the values of buildings completed in the larger municipalities, and wholesale sales of construction and building materials. Since the fourth quarter of last year, the worst performing sub-indicator was labour remuneration, which declined by more than 15%.

“However laudable the policy initiatives announced in this year’s State of the Nation Address and National Budget may be, these will essentially remain only promises unless the stated government objective of closer cooperation with the private sector is translated into active public/private partnerships,” says Botha. “As long as the value of construction works represents only 4% of the country’s infrastructure project pipeline, new jobs will not be created at scale in the construction sector.” a

3,5% The index has returned to its traditional trend of recording a decline between each year’s fourth quarter and the first three months of the following year, recording a drop of 3,5% in the index value

Illegal mining and gangsterism threaten to derail the country’s mining and quarrying industry, unless role players urgently pull together to urgently bring the scourge to a halt, warns surface mining industry association, ASPASA. ASPASA, one of the most vocal organisations on the topic, says the clock is winding down and the South African mining industry is on the brink of a catastrophe if immediate action is not taken. Director Nico Pienaar says the stakes are high and the industry is fast approaching a tipping point.

“Illegal mining puts undue pressure on surface mining companies already struggling spiralling input costs and generally tough trading conditions.

On the contrary, illegal miners seem to operate with impunity, and bypass regulations to undercut prices of legitimate producers,” says Pienaar.

“This is unsustainable and has already led to the demise of many smaller and marginal mines. Perhaps even scarier is the increasing violence of mine invaders and gangsters who have become emboldened to a point where they are now kidnapping mine managers’ families and demanding massive ransoms. Killings and threats are becoming the order of the day and require urgent attention.

“ASPASA has explored several avenues to deal with the issue of illegal mining with little success, despite considerable press coverage and awareness created.

We are however working closely with authorities to supply them with relevant information. a

May/June 2022 | Vol. 1 Issue 3 | www.quarryingafrica.com |

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INDUSTRY NEWS

AfriSam’s composite cements lead in sustainability drive It has been over two decades since AfriSam began accelerating its efforts to reduce carbon emissions from its cement production. This has put the company ahead of the pack, allowing it to reduce the carbon dioxide produced per tonne of cement by some 30%.

The replacement of clinker with other cementitious material has been one of the key aspects of this success.

Hannes Meyer, executive cementitious at AfriSam, highlights that the energy consumed in producing OPC can be 20 to 25% higher than a composite cement, of the same strength class, containing a cementitious extender.

“This results from the added cost of producing a higher percentage clinker at high temperatures used per tonne of composite cement manufactured,” says Meyer. “Extenders like fly-ash or ground granulated blast furnace slag (GGBFS) can be blended into the mix, reducing the amount of clinker milling required per tonne of cement.”

This has more recently become a focus for other players in the market, even those who had previously not embraced the concept of composite cement, he notes. AfriSam has meanwhile become the benchmark for these cement innovations, along with a range of sustainability initiatives to

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South African Road Federation presents G1 course The South African Road Federation (SARF) successfully presented a one-day virtual course on G1 base material on 13 July 2022. The course was facilitated

by Dennis Rossman, a retired SANRAL materials engineer who has a wealth of experience in construction materials.

Basil Jonsson, operations director at the SARF, tells Quarrying Africa that the course handled all practical aspects of the construction process, from material sourcing (specification) through to completion of a G1 crushed stone layer.

The course comes on the back of the new COTO Standard Specifications released in 2020. This has ushered in fundamental changes to what the industry is accustomed to in terms of material requirements. The course addressed a range of changes contained in Chapters 4 and 5 of the new COTO spec, highlighting the responsibilities of the whole value chain, from the material supplier and contractor to the client and the consulting engineer.

“The course was targeted at civil engineers, technologists, quarry managers and laboratory staff responsible for testing G1 material that the quarry manufactures. It highlighted grading specifications that the G1 base material needs to conform to,” says Jonsson. “The course is accredited for Continuous Professional Development (CPD) points by the Engineering Council of South Africa.”

Commenting on the significance of the course, Jonsson says technical staff from quarries need to understand the importance of meeting exact grading specifications when producing G1 base material. A durable base is the foundation of long-lasting roads. “The final road is only as strong as the base on which it is built,” stresses Jonsson. a

monitor and reduce carbon emissions.

“A vital aspect of our use of extenders has been our ability to activate these materials for greater reactivity,” he says. “Through evolving our chemical and mechanical activation methods, we achieve a more reactive product – allowing us to progressively replace more and more clinker while retaining high cementitious quality and strength performance.”

In another stream of the company’s research, it has taken strides in developing the reactivity of clinker itself.

By changing the mineralogy of clinker, its reactivity can be improved. Meyer points out that cement blending companies have already recognised the high reactivity of AfriSam cement, with many of them preferring AfriSam’s products as they ‘go further’ in a blending application.

“We have also had great success in the use of grinding aids in our milling processes, collaborating closely with specialist firms to address our exacting requirements,” says Meyer.

“These grinding aids are specific to the extenders we use, helping to improve

reactivity and in some instances adding 10% to 15% early strength enhancement.”

The end result is that less clinker needs to be produced per tonne of final product, he emphasises, leading to less carbon dioxide being generated. The company has also become more efficient in the use of thermal and electrical energy in its processes. Whereas electricity used to be a minor cost in cement plants, it is now a major factor in cement manufacture. In this context, AfriSam has explored alternative fuels, which have become a major focus for many cement producers globally.

“We have made progress with responsibly disposing of waste products in our energy generation strategies, and we hope that government will take the necessary steps to allow us to expand these initiatives,” he says.

This includes the combustion of waste tyres and industrial carbon sludge, using high-efficiency multi-channel burners that reduce hazardous emissions. He says the employment of increasingly sophisticated process control technology is also part of the ‘AfriSam Way’ towards a sustainable planet. a

Chapter 4 and 5 The course addressed a range of changes contained in Chapter 4 and 5 of the new COTO spec

| May/June 2022 | Vol. 1 Issue 3 | www.quarryingafrica.com

LEAD STORY Scania offers various service vehicles for mining and quarrying operations.

“

As customers look for ways to drive flexibility in their operations, our rental offering is proving to be a great fit for short-term transport tasks and to bridge the long lead times between ordering and delivery of new vehicles.

15 Having joined Scania as a trainee in 2007, Bergvall has held several senior leadership roles during his 15-year career with the company

Erik Bergvall, new MD of Scania Southern Africa.

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KEY POINTS At the start of this year, Erik Bergvall took the reins as MD of Scania Southern Africa

Bergvall’s major focus as MD for Scania Southern Africa is to strengthen the company’s customer proposition, with particular emphasis on the launch of innovations designed to increase customer profitability and operating efficiencies

The total solutions sales approach, which has been one of the key strengths for Scania over the years, will be reinforced to improve the company’s value proposition to the customer

Following the devastating impact of the Covid-19 pandemic from 2020, Bergvall believes that the market has experienced a strong rebound in recent months

| May/June 2022 | Vol. 1 Issue 3 | www.quarryingafrica.com

8x4

Scania offers its 8x4 heavy mining tipper, which has proven to be a cost-effective option to traditional yellow metal haulers

2019

Following the devastating impact of the Covid-19 pandemic from 2020, the market has experienced a strong rebound in recent months

DRIVING SCANIA’S CUSTOMER-CENTRIC APPROACH

Despite the ongoing supply chain challenges, newly appointed MD of Scania Southern Africa, Erik Bergvall, is encouraged by the state of the local trucking market. In a one-on-one with Quarrying Africa, Bergvall envisages a 10-15% growth for Scania this year. A customercentric approach and the rollout of innovations designed to increase customer profitability and operating efficiencies, will be key to the company’s growth.

By Munesu Shoko.

There is a Scania for every stage, all the way from in-pit applications and outbound hauling to service vehicles and concrete mixers.

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t the beginning of this year, as part of the Scania Group’s recent changes to its commercial operations, with a view to strengthening its regional hubs, Erik Bergvall took the reins as MD of Scania Southern Africa. Having joined Scania as a trainee in 2007, Bergvall has held several senior leadership roles during his 15-year career with the company.

Having spent the first six years of his Scania career at its head office in Sweden, he moved to Germany in 2014, where he held two leadership roles, initially as dealer manager and then as regional director, responsible for the Northwest Region at Scania Germany.

In 2019, he was appointed MD of Scania Middle East, where he delivered strong growth in both vehicle sales and aftersales, and also introduced several new sustainable transport solutions to the Gulf region.

May/June 2022 | Vol. 1 Issue 3 | www.quarryingafrica.com |

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LEAD STORY

From a product perspective, the Scania NTG offers a full range of trucks that can work across several application areas within the quarrying environment.

Major focus

State of the market

Bergvall’s major focus as MD for Scania Southern Commenting on the state of the market, Africa is to strengthen the company’s customer Bergvall says demand for commercial vehicles proposition, with particular emphasis on the is on a positive trajectory. Following the launch of innovations designed to increase devastating impact of the Covid-19 pandemic customer profitability and operating efficiencies, from 2020, the market has experienced a as well as to reinforce the company’s total strong rebound in recent months. solutions approach.

Bergvall says the mining industry – the “We have a strong sustainability agenda, and transportation of raw materials in particular – is within the next few months we will communicate the biggest demand driver for Scania at the some exciting news with regards to new product moment. The commodity market is enjoying launches, as well as our view on electrification,” a “bull run” with prices of several commodities says Bergvall. “The mission is to enhance reaching historic highs. Given the strong efficiency and optimise total cost demand for both its products and of ownership for our customers, services, Scania Southern Africa all whilst lowering their expects a 10-15% growth of its environmental impact.” business in 2022.

On a global scale, Scania “We offer a number of 2019 reports increased demand solutions to the mining and for its low-emission engine quarrying markets. The In 2019, Bergvall was appointed technology, in line with most important for us is the MD of Scania Middle East, where the changing legislation. transportation of material he delivered strong growth in both vehicle sales and This is also being driven by from the processing plants aftersales, and also introduced corporate clients seeking to the harbour or to the several new sustainable transport solutions to to meet the ESG targets. end customer. Most of our the Gulf region “We are positive about customers in this market the uptake of alternative segment are running this type solutions in the local market as of solution. We are also active in forward-thinking companies seek in-pit operations, where we offer to play a pioneering role in reducing our 8x4 heavy mining tipper, which emissions and to be part of the cleaner has proven to be a cost-effective option to environment revolution,” he says. traditional yellow metal haulers,” he says.

While the lack of legislation remains the Scania also offers various service vehicles stumbling block to the effective rollout of for mining and quarrying operations. The low-emission engine technology in South Scania modular approach also provides great Africa, Bergvall says Scania is in favour of opportunities to tailor solutions to specific the sustainability agenda and, together with customer and application requirements. customers, the company will play an active role Supply chain issues in the rollout of clean engine technology. He Amid growing demand, supply chain issues also believes that the availability of low sulphur continue to hamper the flow of products diesel supports the effective rollout.

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| May/June 2022 | Vol. 1 Issue 3 | www.quarryingafrica.com

Scania offers various service vehicles for mining and quarrying operations.

worldwide. The semiconductor shortage Africa. The total solutions sales approach, also remains a challenge for global original which has been one of the key strengths for equipment manufacturers (OEMs). Consequently, Scania over the years, will be reinforced to the lead times for new trucks have become improve the company’s value proposition to longer than during the pre-Covid era. the customer.

However, Bergvall believes that the situation Bergvall strongly believes that fleet operators is improving, and Scania is working hard want to have a single point of call for their to mitigate the impact of the situation on vehicles, along with relevant services, including customers. “We are in a much better position, financing and insurance. As customers want to and we should see an improvement going focus their efforts on fulfilling their transportation forward, which will result in better lead times for obligations to their clients, they want reliable our customers,” he says. partners to support them as much as possible, Bergvall says customers have also come to not only with the vehicle, but with all other understand that supply chain issues are services around it. a global problem and are not unique “We are therefore taking big to one OEM. To help mitigate steps to improve our total the impact of the supply chain solutions sales approach issues, Scania is working by integrating all our closely with its customers to commercial activities 10-15% understand their needs, to into one package for the determine which orders can customer,” he says. “We are Given the strong demand for both its products and services, be postponed and identify moving to integrate our Scania Southern Africa circumstances where rental Scania Finance facility into expects a 10-15% growth solutions can help plug the the rest of our commercial of its business in 2022 stock gaps. activities to create a single In fact, Scania has seen interface for the customer.” a big demand for its rental In addition, Scania offering as customers look for recognises the need for a strong ways to sidestep the long lead skills development strategy. The times for new trucks. “We have seen company has established its own a big demand for our rental services, academy, which acts as a training base for perhaps because of the waiting time for new technical skills, the lifeblood of its activities. vehicles,” he says. “As customers look for ways “We have a strong focus on skills to drive flexibility in their operations, our rental development. We consider ourselves a offering is proving to be a great fit for short-term premium brand and should therefore always transport tasks and to bridge the long lead times deliver premium services. Ultimately, it’s the between ordering and delivery of new vehicles.” people who deliver these services to customers and we must therefore be at the forefront Key initiatives of developing the skills we need to improve To further grow the business, Bergvall will drive our service levels to the customer,” concludes a number of initiatives at Scania Southern Bergvall. a | May/June 2022 | Vol. 1 Issue 3 | www.quarryingafrica.com

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QUARRY VISIT

An aerial view of Laezonia Quarry.

WINNING THE COST CONTROL BATTLE With its complex geology, characterised by five rock types, predominantly amphibolite, PPC’s Laezonia Quarry has traditionally been deemed one of the most expensive operations to run in South African quarrying circles. However, a number of cost-cutting initiatives are helping the quarry win the cost control battle.

Munesu Shoko was recently on site and filed this report for Quarrying Africa.

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ggregates by their very nature are high-volume, lowcost materials. For quarries to mine and process profitably, they need to watch their cost base and drive efficiencies in every aspect of their operations. This was the overarching message from Quarrying Africa’s recent visit to PPC Laezonia’s aggregate quarry, where cost-cutting initiatives have helped counter several operational challenges on site.

A key challenge at PPC Laezonia is the complex geology, which contains five rock types in one pit. The primary

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rock type is amphibolite, which occurs together with migmatite, schist, weathered and competent granite.

With a relative density of 2,9, amphibolite is a coarse-grained metamorphic rock which is known for its hardness to blast and process. Migmatite, with a relative density of about 2,7, is an equally tough rock to crack.

Mining amphibolite is no walk in the park, says Arthur Ndindani, GM PPC Aggregate Quarries. The hard nature of the rock presents a lot of costrelated challenges from a blasting and processing perspective. It is hard to

| May/June 2022 | Vol. 1 Issue 3 | www.quarryingafrica.com

280 tph

Good fragmentation has helped increase production of migmatite material from the previous 250 tph to 280 tph

PPC developed a separate sand pit on the southern side of the existing mining area. The deeply weathered granite in this area is freedig material, which eliminates the need to drill and blast.

break and is unforgiving on wear items such as crusher liners, which increases the cost of operation quite significantly.

In fact, says Ndindani, PPC Laezonia has traditionally been famous for being one of the costlier quarries to operate. There is one other quarry in the Gauteng region with a comparably tough rock; an andesite operation operated by a major competitor.

However, PPC Laezonia also leverages these geological challenges to produce highly soughtafter material. Despite its hardness to process, amphibolite remains one of the operation’s key competitive edges, says Innocent Magagula, works manager at PPC Laezonia. Due to its high uniaxial compressive strength, the rock has traditionally been the preferred choice by the road-making industry. Because it doesn’t weather quickly, it makes durable and long-lasting roads.

While the different rock types on the same bench are a nightmare from a mining perspective, they also allow the quarry to produce a wide variety of materials to cater for different market segments, from road-making to roof tile production and concrete products manufacturing (CPM).

To change the fortunes of the quarry, the management team reviewed some of the old processes in 2019. This resulted in the orchestration of a number of successful costcutting initiatives which have put PPC Laezonia on a completely different trajectory over the past three years. The cost-cutting measures have been

330 tph

Production of amphibolite material has increased from around 300 tph to 330 tph

A view of the plant area at Laezonia.

KEY POINTS A key challenge at PPC Laezonia is the complex geology, which contains five rock types in one pit. The primary rock type is amphibolite, which occurs together with migmatite, schist, weathered and competent granite With a relative density of 2,9, amphibolite is a coarse-grained metamorphic rock which is known for its hardness to blast and process To reduce the cost of operation, the mining team recently developed a separate sand pit on the southern side of the existing mining area. The weathered granite in this area is free-dig material, which eliminates the need to drill and blast To get the better of poor fragmentation, the quarry migrated from shock tube to electronic blasting in 2019

implemented to enable the quarry to extract each rock type efficiently to improve the cost per tonne of each product.

Weathered granite

Used for the production of two types of sand, river sand and building sand, the weathered granite rock has traditionally been mined in the main pit. At other operations, depending

May/June 2022 | Vol. 1 Issue 3 | www.quarryingafrica.com |

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QUARRY VISIT

A Volvo excavator loading a 30-t Bell ADT in the sand pit.

on product lines, this type of rock would normally be discarded as overburden material.

At PPC Laezonia, it is competent enough to be processed as sand material. In fact, says Magagula, the quarry prides itself on its unique -5 mm washed river sand, which is used for the manufacturing of roof tiles.

“Previously, we used to drill and blast this material in the main pit,” says Ndindani. “This was done mainly to expose the amphibolite rock, which at the time was the main demand driver.

However, from around 2019, we saw a big decline in the demand for road stone. We looked at our deposit and identified an opportunity to develop a separate sand pit on the southern side of the existing mining area. The deeply weathered granite in this area is free-dig material, which eliminates the need to drill and blast. We just dig with an excavator and load the material for processing. It’s such a huge cost-saving for us.”

When developing the new sand pit, the team also considered the shortest haul route possible, from the pit to the sand-processing plant, which was another key initiative in the quest to cut operational costs. Initially, the haul distances were about 800-900 m from the pit to the processing plant. Since the pit has advanced further over recent years, the haul distances are now about 1-1,2 km.

“The short haul distances translate into reduced diesel burn on site, which drops our litres of fuel per tonne significantly. In addition, the free-dig material comes with a relative density of about 2,2, which makes it easier to process. That, together with the short haul distances, translates into increased productivity,” explains Magagula.

“Previously, the primary plant on sand mode was running at 250 tonnes per hour (tph). Since the introduction of the free-dig material, we have increased production to about 350 tph.”

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Processing free-dig material has also resulted in the extended life of jaw liners, translating into reduced maintenance costs of the sand plant.

Having previously changed the jaw liners after every four months, the maintenance team now only changes the same liners about once per year. This is a massive cost saving, says Ndindani, because jaw liners are generally an expensive wear item.

In terms of production, the weathered granite is processed at the sand plant. The feed size ranges from fines to 700 mm. This is fed into a primary Osborn 3042 jaw crusher with a closed side setting of 80 mm. From the jaw, there are two conveyor belts running up to the sage pile.

Underneath the sage pile there is a conveyor that takes material to the tertiary plant. Here, there is a screen that takes out building sand (-3 mm), which is used mostly in the construction industry.

From here, anything above -3 mm goes upstream for washing to produce the flagship -5 mm river sand, which is predominantly used for making roof tiles. For shaping purposes, the sand is also put through a special vertical shaft impactor (VSI) from Techroq.

Migmatite

The migmatite material is predominantly used to produce sub-base material (G1 and G5) for the road industry. This is mined from the main pit. Like the amphibolite, migmatite is a highly metamorphised rock, which makes it hard to process.

Traditionally, fragmentation has always been a major concern. The high compressive strength of the rock proved too much to handle for the pyrotechnic blasting technique, the shock tube, previously employed at the quarry. Consequently, the blast process would not achieve the required fragmentation, and the blasting team would always end up with “a farm of boulders” on the ground, which called for costly secondary

| May/June 2022 | Vol. 1 Issue 3 | www.quarryingafrica.com

QUARRY VISIT blasting or further mechanical breaking of selectively because the demarcations of each the rock using an excavator equipped with a rock type are very clear.” hydraulic hammer.

Amphibolite In fact, says Magagula, the quarry previously The amphibolite rock is used to produce road had a permanent excavator with a hydraulic stone and aggregates at large. The material is hammer deployed to break oversize material in the produced at the same plant as the migmatite. pit. Depending on quantity, the cost of breaking It goes through the same Osborn 4248 jaw oversized material using mechanical means can be crusher before reporting to the secondary up to four times higher than the cost of an initial Symons crusher. It then goes through two blast. The cheapest way of breaking rock, stresses screens before it reports to the sage pile as Ndindani, is through explosives.

80 mm material. From here, material is fed To get the better of poor fragmentation, the to the road stone plant via a tunnel feeder quarry migrated from shock tube to electronic underneath the sage pile. blasting in 2019. The preferred supplier is BME, Material then goes through a series of screens which supplies its flagship Titanium electronic before it gets to a tertiary crusher, a Sandvik blast detonation system. Despite the high upfront CH440. From here, it is fed into a Techroq VSI cost of electronic compared to shock tube for shaping. Different end sizes are produced, blasting, Magagula says the benefits of good including 19 mm (mostly for readymix concrete), fragmentation on the downstream processes 13 mm (road stone), 9 mm and 6,7 mm. These such as load and haul as well as crushing are products are all washed to remove impurities, massive and outweigh the initial capital outlay. which increases their value in the market. The “BME is our preferred explosives supplier. Since process also produces washed crusher sand testing the company’s Titanium electronic blast (-5 mm), which is largely supplied to CPM and initiation system at our sister quarry, Mooiplaas, asphalt markets. we have never looked back,” says Magagula. “We Here, the migration from shock tube to have seen a very big change in terms of electronic blasting has also yielded fragmentation of the muckpile.” massive gains. Good fragmentation Improved fragmentation has allows for choke feeding of a massive positive impact on crushers, which in turn results in the downstream processes, increased production. In fact, including better penetration 100% production of amphibolite when loading with an material has increased from excavator, which in turn Crusher liner life on the secondary Symons crusher has improved by around 300 tph to 330 tph. improves the loading rate 100% from the previous three to Meanwhile, maintenance and cycle times. With the six months costs in the plant have introduction of electronic significantly gone down, blasting, the quarry has seen a mainly due to increased life of drastic improvement in its cycle liners. For example, liner life on times. At the plant, they no longer the secondary Symons crusher has feed oversize material into the jaw improved by 100% from the previous crusher, which improves the tph, while three to six months. reducing the wear rate of jaw liners. Production “On the primary jaw crusher, we would of migmatite material has since jumped from the previously change the swing liner every six previous 250 tph to 280 tph. months, while the fix liner would have to be In terms of the process, the migmatite run-ofturned. We are now changing the swing liner quarry material is fed into an Osborn 4248 jaw every eight months,” explains Magagula. crusher with a closed side setting of 132 mm. It Apart from winning on the cost front, PPC then goes through a secondary crusher, a Symons Laezonia has achieved a safety milestone, 5½, before reporting to screen one. From here, the reaching 13 years of no Lost Time Injury (LTI) in material is sent to another Symons crusher, before 2022. The most crucial step in the prevention of it is sent to screen two for final sizing. accidents has been the focus on proper training “The migmatite occurs in the same bench of all employees who work at the quarry. as the amphibolite and weathered granite.

“We also encourage proper risk assessments Previously, the mining team resorted to slot before doing any task on site. All the employees mining to expose the required rock at a given are also trained in every aspect of their jobs, from time, which called for small and isolated blasts. code of practices to load and haul. The quarry Because explosives are expensive to buy and foreman is also a holder of an EMS certificate, transport to site, this approach proved costly,” which speaks directly to our uncompromising says Ndindani. “From 2019, we changed the attitude towards safety,” concludes Magagula. a strategy and now blast the whole face and load

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| May/June 2022 | Vol. 1 Issue 3 | www.quarryingafrica.com

QUARRY VISIT Bon Accord Quarry has commissioned the first locally manufactured FastPlant from Sandvik Rock Processing.

A NEW ERA OF QUARRYING EFFICIENCY

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Having previously experienced incessant issues with its old processing plant, City of Tshwane’s Bon Accord quarry has taken delivery of the first locally manufactured FastPlant from Sandvik Rock Processing. Commissioned in May this year, the fully automated 220 tonnes per hour (tph) capacity plant has ushered in a new era of efficiency, boosting the quarry’s production by almost 80%, writes Munesu Shoko.

stablished in 1904, Bon Accord quarry is owned and operated by the City of Tshwane. The operation was established to meet the municipality’s material needs for the construction and maintenance of its roads. In 2014, the quarry had to close its doors due to issues with the processing plant.

Mine manager Johan Marx tells Quarrying Africa that the old crushing plant was built in phases more than 50 years ago and had never been refurbished. Owing to aged infrastructure, it experienced constant breakdowns, which made it difficult to operate efficiently. It also posed health and safety risks because of the rusting steel structures, worn-out foundations and footing, making it non-compliant with the stringent Mine Health and Safety Act (MHSA).

In fact, the old plant was issued a section 54 notice by the Department of Mineral Resources and Energy (DMRE) for falling short of the MHSA regulations. During the operation’s closure, the

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city had to acquire aggregates from a nearby commercial quarry for use at its asphalt plant.

This, says Marx, was a costly exercise, which necessitated the reopening of Bon Accord quarry in May this year.

To restart operations, a decision was made to procure a completely new plant. Refurbishing the old one was out of the question as the cost would surpass that of buying a new, modern plant. The FastPlant concept from Sandvik Rock Processing appealed to quarry management, mainly because of the fast delivery and installation, allowing the quarry to start production sooner.

FastPlant is a range of pre-defined crushing and screening plants made for the most common mining and quarry applications, reducing waiting time, maximising uptime and increasing profitability. Delivery generally takes about 12-14 weeks ex works, as opposed to double or thrice the timeline of a custom-designed plant.

“We also considered the long-term future of the quarry. Longevity and reliability were therefore

| May/June 2022 | Vol. 1 Issue 3 | www.quarryingafrica.com

220 t

The new FastPlant produces 200 t per hour

5-million m³

The plant is designed to last for the rest of the quarry’s life, which is about 50 years, with a potential 5-million m³ material still to be mined

The life of quarry is about 50 years, with a potential of 5-million m³ material still to be mined from the mountain.

KEY POINTS In 2014, the City of Tshwane’s Bon Accord quarry had to close its doors due to issues with its old processing plant In May this year, the quarry restarted operations following an investment in a new FastPlant from Sandvik. This is the first locally manufactured FastPlant to be commissioned Commissioned in May this year, the fully automated 220-t capacity plant has boosted the quarry’s production by almost 80% The FastPlant concept from Sandvik Rock Processing appealed to quarry management, mainly because of the fast delivery and installation, allowing the quarry to start production sooner

key factors in our decision-making. From an equipment point of view, we wanted something that would last us for the rest of the quarry’s life, which is about 50 years, with a potential of 5-million m³ material still to be mined,” says Marx.

The plant is designed to last the projected lifetime of a mine, says Jaco Benade, project manager – Crushing and Screening, at Sandvik.

With its plug-and-play nature, components can be easily exchanged as and when required. It is also possible to upgrade to larger crushers such

as the new 800i series if ever the need arises.

The conveying system is already designed to meet any future increases in tonnages. “We have gone for the 600 mm conveyors feeding the crushers, which can cater for a substantial increase in production. The screen is also generally designed to allow for increase in capacity,” says Benade.

Every piece of equipment is as good as its aftermarket support. With that in mind, the management team of Bon Accord quarry also considered a supplier with a good track record in not only supplying equipment, but also offering sound backup support to ensure maximum plant uptime. “Sandvik’s track record speaks for itself,” says Marx.

The plant

While Sandvik has been offering the concept for a while, this is the very first locally manufactured FastPlant, confirms Benade, who adds that a total of 200 t of steel, all-inclusive, went into the production of the plant.

The deal was negotiated right in the middle of the hard lockdown in 2020. The order was placed during Level 5 of the lockdown, with manufacturing commencing during Level 4. Despite the challenges brought about by the restrictions, compounded by the global supply chain disruptions, the plant was still delivered on time.

Sandvik collaborated with several longstanding partners on the project, mostly black-

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QUARRY VISIT

Run-of-mine material is tipped into a grizzly ST feeder, before it goes through a pre-screen to remove natural fines.

empowered companies, for steel design and fabrication, MCC design and fabrication with instrumentation as well as electrical installation on site. TCT was appointed by Bon Accord to conduct the civils, installation and site management. One of the key challenges during installation was the need to remove the old plant first as the new one needed to be installed in the same place as the existing plant.

The new plant comprises a full suite of Sandvik equipment, including jaw and cone crushers, screens and feeders. Run of mine is tipped into a grizzly ST feeder, before it goes through a prescreen to remove natural fines, before material is sent to a Sandvik CJ411 jaw crusher, which can take a top size up to 750 mm. The plant design specified a 600 mm top size capability.

From there, material reports to the first storage bin, which then feeds the Sandvik CH430 secondary cone crusher. It crushes material down to about 30 mm. Material then goes through a screen before it reports to the Sandvik CH440 tertiary cone crusher which crushes down to about 12 mm.

Notably, both the cone crushers come with Sandvik’s Automatic Setting Regulation (ASRi) control system. ASRi, explains Benade, delivers real-time performance management, enabling the plant operator to monitor and optimise crusher performance and productivity.

The ASRi system allows the plant to preload crusher programmes as per the requirement of the client and the close side setting can even be adjusted during operations. The system continuously optimises crusher performance

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without overloading it. The ASRi system allow the operator, with the touch of the screen, to automatically calibrate the crusher and re-adjust crusher settings to compensate for crushingchamber wear – ensuring consistent product size.

The plant also has a human machine interface (HMI) which gives a user-friendly overview of the system, allowing the plant operator to troubleshoot faster and more efficiently. The HMI also displays minor and major alarms for the system, which can also be easily bypassed, if not critical, in order to maintain production and increase uptime.

Benefits abound

Within three months of operation, the plant has already proved to be a worthwhile investment for Bon Accord. Due to the high efficiency of the plant, Marx tells Quarrying Africa that production has already increased by about 80% compared to the previous plant. The installed capacity of the plant is 220 tonnes per hour (tph), producing crusher sand and various sizes of stone, including 7 mm, 10 mm, 14 mm, 19 mm and G1 base material.

“We have, however, recently tested production of a 32 mm stone, and the plant punched well above its capacity to produce 275 tph,” says Marx. “At the moment, we are largely producing crusher dust and 9 mm stone for the asphalt plant, which is producing between 150 and 180 t of asphalt per day. Given the extra capacity we have on the crushing plant, we will in future sell aggregates to the external market, which

| May/June 2022 | Vol. 1 Issue 3 | www.quarryingafrica.com

A view of the Sandvik CH430 tertiary cone crusher, which forms part of the new plant.

Within three months of operation, the plant had already proved to be a worthwhile investment for Bon Accord.

will allow us to generate some much-needed revenue for the city.”

Marx is also thrilled by the ease of maintenance of the plant, which is enhanced by the automation system. The previous plant, he says, had 12 major components. It did not have any form of sensors to monitor the different parameters of the plant, which called for manpower on every major component. Consequently, the old plant was run by 12 people at any given time. In contrast, the new plant is currently being run by five people,

one in the control room and four on the belts.

“The automation system is impressive,” says Marx. “If something goes wrong on any part of the plant, the system quickly picks up where the problem is. If, for example, a certain belt is tripping, the plant stops itself and informs the operator where the issue is. Unlike the previous plant, we don’t need to run with trip wires to dictate where the issue is. The ease of operation and maintenance is a big plus in our quest for maximum uptime and productivity.” a | May/June 2022 | Vol. 1 Issue 3 | www.quarryingafrica.com

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DIGITAL QUARRY Equipped with leading-edge automation technology, the SmartROC T45 delivers optimised drilling processes.

REALISING THE DIGITAL QUARRY With Epiroc’s 6th Sense, the industry’s quest for a digital quarry – one that uses digital solutions to empower quarry owners to make better decisions, remove people from harm’s way and make a significant difference to how quarries go about their business – is firmly upon us. By Munesu Shoko.

A

s the quarrying industry adapts to the changing operational environment, quarry owners are increasingly looking to digital technologies to enhance productivity, efficiency and take people out of harm’s way. Eeje van Jaarsveld, business line manager – Technology and Digital at Epiroc South Africa, tells Quarrying Africa that the uptake of digital solutions at quarries in southern Africa is largely being

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driven by contractors.

“Most of our digital technologies in the local quarrying space are adopted by drilling contractors, because quarries in the region generally outsource their drilling functions to contractors,” he says.

While quarries generally lag behind their mining counterparts when it comes to digital transformation, Van Jaarsveld believes that as the industry transitions through the current crisis and aims to thrive in the ‘new normal’, there is a window of

| May/June 2022 | Vol. 1 Issue 3 | www.quarryingafrica.com

6th Sense

With 6th Sense comes a great focus on system connectivity, using interoperability to unlock the full potential of automation for production gains at lower operating costs

100 m

BenchREMOTE enables operators to work at a safe distance of up to 100 m

Epiroc’s Mobius for Drills enables multivehicle command, control and monitoring to maximise productivity and safety.

KEY POINTS As the quarrying industry adapts to the changing operational environment, quarry owners are increasingly looking to digital technologies to enhance productivity, efficiency and take people out of harm’s way The 6th Sense is Epiroc’s way to optimise the industry’s value chain through automation, system integration and information management – enabling smart, safe and seamless operations Automated and tele-remotely controlled operations can significantly increase productivity and improve safety at the same time Optimisation, one of the foundational elements in Epiroc’s digital journey, enables processes to be executed and equipment to be operated with full potential through improved efficiency and higher utilisation

“

Peter Drucker once said ‘culture eats strategy for breakfast’. Without people or culture alignment, technology implementation will not get the desired results, because people are responsible for executing the strategy.

Eeje van Jaarsveld, business line manager – Technology and Digital at Epiroc South Africa

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DIGITAL QUARRY

With My Epiroc, quarry owners have instant access to all their machines’ data.

opportunity to accelerate digital transformation and advance the future of quarrying.

The 6th Sense is Epiroc’s way to optimise the industry’s value chain through automation, system integration and information management – enabling smart, safe and seamless operations.

With 6th Sense comes a great focus on system connectivity, using interoperability to unlock the full potential of automation for production gains at lower operating costs.

6th Sense in detail

The 6th Sense entails three major legs – Machine Automation, Process Automation and System Integration, explains Van Jaarsveld.

Three foundational elements – Insights, Control and Optimisation – are key to achieving Machine Automation, Process Automation and System Integration.

The system outputs of Epiroc’s 6th Sense approach are increased productivity, efficiency and safety. To achieve these outputs, Epiroc’s implementation focus considers people, processes and technology maturity.

“Machine automation entails various systems developed to ensure that an individual machine performs optimally, while process automation is all about systems developed to ensure the process performs optimally. System integration means that systems are developed to tie together the optimised portions of the value chain to operate as an ecosystem,” explains Van Jaarsveld.

Insight – transparent information in support of good decisions – is the starting point to reaching the three pillars of digitalisation. Data, stresses Van Jaarsveld, is key in the modern world. The massive amounts of data being generated in daily operations only turn into true value if retrieved, stored and analysed in a timely manner.

The 6th Sense Insight product family therefore comprises solutions for collecting, transferring,

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storing, visualising and analysing the data, transforming it into useful information for better decision making. These include My Epiroc, Telematics, Analytics, Rig Remote Access, Measure While Drilling, MineRP InterOp, Mobius for Drill and Surface Manager.

Automation

As part of the Control pillar, quarry operators can use various machine automation technologies from Epiroc to increase productivity in a safe, consistent and predictable way. “Automated and tele-remotely controlled operations can significantly increase productivity and improve safety at the same time. Automation can also increase consistency of daily operations and provide predictable results,” says Van Jaarsveld.

One example of Epiroc’s automated solutions that can be of great benefit to the quarrying industry is the fully autonomous SmartROC D65 surface drill rig. SmartROC D65 consistently delivers high-quality blast holes with accuracy and precision. It is loaded with smart features such as automated drilling and rod handling. The automation-ready platform also includes an Auto Feed Fold option. With a single action, the Auto Feed Fold enables the operator to fold the feed for tramming or position it for drilling.

The BenchREMOTE option – a remote operator station designed to control SmartROC rigs – makes it possible to remove the operator from dangerous areas. It enables operators to work at a safe distance of up to 100 m. BenchREMOTE can handle up to three SmartROC rigs in parallel – taking productivity to a new level. Thanks to an automated drill cycle, BenchREMOTE can control up to three SmartROC rigs at the same time. This dramatically increases operator productivity. Each BenchREMOTE can be pre-programmed to recognise ten rigs, making the planning process easier.

Optimisation, one of the foundational elements

| May/June 2022 | Vol. 1 Issue 3 | www.quarryingafrica.com

DIGITAL QUARRY

BenchREMOTE makes it possible to remove the operator from dangerous areas.

6TH SENSE TO CUSTOMER VALUE

The 6th Sense is Epiroc’s way to optimise the industry’s value chain through automation, system integration and information management – enabling smart, safe and seamless operations.

in Epiroc’s digital journey, enables processes to be executed and equipment to be operated with full potential through improved efficiency and higher utilisation. Some of Epiroc’s products in the 6th Sense Optimise family include High Performance Development, Stope Optimisation, Transport Loop Optimisation and Application Expertise Services.

Implementation focus

For customers to achieve the required outputs of their digitalisation strategies, Epiroc considers three important elements as part of the implementation focus – people, processes and technology. People, says Van Jaarsveld, are central to the success of any digitalisation strategy.

“As part of the implementation focus, we look at the people. Before any technology implementation takes place, we need to understand the people working on site, because any strategy is only as good as the workers. It’s important to determine whether the people in the organisation understand the technology and identify areas of improvement

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necessary for the strategy to realise the desired value cases,” he says.

“Peter Drucker once said ‘culture eats strategy for breakfast’. Without people or culture alignment, the technology implementation will not get the desired results, because the people are responsible for executing the strategy,” adds Van Jaarsveld.

Processes are important in Epiroc’s implementation focus. Before the technology rollout, Epiroc looks at the operation’s existing processes. For example, does the quarry use a drill plan in its drilling process? This helps to establish the level of process maturity on site or within the organisation.

“It’s important to understand the current processes and capabilities on site. People and processes determine whether the technology implementation will be successful or not – there is no magic fix. If a site has the necessary peopleculture alignment and the processes are mature, it becomes easy to adopt digital technologies,” concludes Van Jaarsveld. a

| May/June 2022 | Vol. 1 Issue 3 | www.quarryingafrica.com

PAYLOAD MANAGEMENT Loadrite 360 connects the loader and scale house to provide data sharing of loadout jobs which result in greater efficiency, improved visibility and higher product sales.

OPTIMISING LOADOUT PROCESSES Loadtech, the authorised Loadrite distributor in sub-Saharan Africa, is introducing the Loadrite 360, a digital job order system that improves loadout efficiency by automating the process from order to delivery. It provides a 360-degree view of quarry loadout operations between the onboard loader scale, the weighbridge and the quarry manager, thus helping quarries improve their accuracy and speed of loadout processes.

By Munesu Shoko.

A

mid a growing uptake of load weighing systems in the sub-Saharan Africa market, Loadtech is debuting the Loadrite 360 payload management system to help mines and quarries get the best out of their loadout operations. Speaking to Quarrying Africa, Glen Webster,

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sales director of Loadtech, says the company is currently trialling the first units at one of the leading aggregates providers’ 15% quarries.

The Loadrite 360 – a Loadtech has recorded a loadout automation and substantial 15% business growth in reporting system for quarry the past three years loadout activities – consists of a wheel loader onboard scale, an automated communications connection and a performance reporting tool. Jobs are entered in the office and selected in the loader,

| May/June 2022 | Vol. 1 Issue 3 | www.quarryingafrica.com

360°

The Loadrite 360 provides a 360-degree view of quarry loadout operations between the onboard loader scale, the weighbridge and the quarry manager

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Loadtech has been a Loadrite dealer for the past 24 years, and today the company is one of our most trusted and experienced dealers in the world

KEY POINTS Amid a growing uptake of payload management systems in the sub-Saharan Africa market, Loadtech is debuting the Loadrite 360 data management system to help mines and quarries get the best out of their loadout operations Loadrite 360 connects the loader and the weighbridge so as to provide data sharing of loadout jobs, resulting in greater efficiency, improved visibility and higher product sales Although the Loadrite 360 is primarily a tool to improve the accuracy and speed of loadout operations, it can also reveal hidden improvement opportunities With the Loadrite 360, quarry operators can reduce fuel and maintenance costs by avoiding unnecessary idling of loaders and trucks in loadout

reducing data entry, eliminating mistakes and improving customer satisfaction.

Sören Schramm – channel development manager EMEA at Loadrite, says the technology is designed to transform the way in which quarries have always conducted their loadout processes. Traditionally, operations have relied on weighbridges alone. These are

“

With the Loadrite 360, quarry operators can reduce fuel and maintenance costs by avoiding unnecessary idling of loaders and trucks in loadout.

It also provides quarries with increased truck visibility to ensure that trucks are loaded to capacity in the shortest time possible.

Glen Webster, sales director of Loadtech

| May/June 2022 | Vol. 1 Issue 3 | www.quarryingafrica.com

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PAYLOAD MANAGEMENT

The Loadrite 360 can holistically improve loadout operation through performance metric tracking, job data automation and real-time 360° job visibility.

known to be prone to product errors and weight challenges.

more time for loading.

The Loadrite 360 in-cab indicator clearly presents a list of loadout jobs in order of Benefits abound priority by truck registration. By providing With the Loadrite 360, aggregate producers can simple, relevant and prioritised job data to the turn their workflows around – literally. Instead operators, they are empowered to complete of having a weighbridge at the exit, it could be jobs more quickly across the site with no loss in moved to the entrance area, where information loading accuracy. The list of loadout jobs also about the truck – including the registration, provides richer loadout job queue data and thus tonnage and product required – is captured reduces verbal communication errors and truck and relayed to the loader. As soon as the truck waiting time. drives in, the loader operator already knows The system uses shared visibility of the quantity and type of material to payload data, job data automation be loaded. This reduces loading-, and performance metric tracking waiting- and idle-times. to highlight opportunities “The Loadrite 360 can for improvement. The holistically improve loadout performance reports track 100% operation through performance loader metrics including tons metric tracking, job data per hour (tph) across multiple Loadtech has grown its technical automation and real-time 360° or individual loaders, actual team, which is key to its job visibility. It connects the time spent on truck loading support capabilities, by almost 100% in the past loader and the weighbridge so activities and loader operator two years as to provide data sharing of efficiency which highlights loadout jobs, resulting in greater staff training needs. efficiency, improved visibility and With the InsightHQ reporting higher product sales,” says Schramm. option, managers can monitor The two-way automated site production and performance communication shows jobs requested at the anywhere, at any time, on any mobile weighbridge as a job list on the scale inside the device or web browser. InsightHQ also allows loader cab and completed loadout data is fed centralisation of data from excavator and belt directly into the weighbridge ticketing system. scales.

This reduces double entry work and data entry “Although the Loadrite 360 is primarily a errors for both the operator and the weighbridge tool to improve the accuracy and speed of attendant. Accurate on-screen job data reduces loadout operations, it can also reveal hidden error-prone verbal communications and allows improvement opportunities,” says Schramm. “The

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| May/June 2022 | Vol. 1 Issue 3 | www.quarryingafrica.com

The Loadrite 360 consists of a wheel loader onboard scale, an automated communications connection and a performance reporting tool.

system enables users to drill into production data to see individual trucks, loaders or even bucketby-bucket data and identify opportunities to improve.”

“With the Loadrite 360, quarry operators can reduce fuel and maintenance costs by avoiding unnecessary idling of loaders and trucks in loadout. It also provides quarries with increased truck visibility to ensure that trucks are loaded to capacity in the shortest time possible,” adds Webster.

Loadtech has recorded a substantial 15% business growth in the past three years, confirms Webster. “Covid-19 has taken some of the competitors out of business and this has contributed to about 5% of our growth in the past two years. The remaining 10% is purely new business driven by the increased uptake of these solutions in the local market,” he says.

The sound support structures have also been key to Loadtech’s success. For example, the company has a dedicated data specialist who works closely with customers to help Increased uptake them interpret and make sense Schramm tells us that, in recent of the data generated by the years he has observed increased Loadrite systems. This, says uptake of load weighing systems Schramm, makes a significant in Africa, as local mines and difference in customer 24 - 48 quarries began to see the value operations. of digital systems. Loadtech’s “Data is one thing and Loadtech can now guarantee growth in the past two to making sense of it is its customers a 24-48-hour three years, he says, is a clear quite another. Having a turnaround for any technical issues. indication that the market is dedicated data specialist maturing. is therefore a big benefit “Loadtech has been a Loadrite for customers who need to dealer for the past 24 years, and translate data into workable today the company is one of our most solutions for their businesses,” trusted and experienced dealers in the says Schramm. world. In the past few years, they have done “We have also grown our technical very well for us. We believe it is largely to do team, which is key to our support capabilities, with the maturity of the local market, which is by almost 100% in the past two years. now ready for digitalisation of processes. Some, Consequently, we can now guarantee our however, still operate in the ‘stone age,’ but the customers a 24-48-hour turnaround for any majority of customers now understand what technical issues. We also offer continuous they have to do to survive in such a cut-throat operator training and stay connected with all business environment,” explains Schramm. our customers,” concludes Webster. a

SCALPING SCREEN

JACK OF ALL TRADES Amid increasing demand for scalping screens across all tiers of the crushing and screening market, Pilot Crushtec International is debuting Metso Outotec’s Lokotrack ST2.3 in southern Africa. Brought in to plug a product gap in the entry-level contractor market, you could think of it as the ‘Swiss Army Knife’ of screening, given its ability to process various feed materials across both primary scalping and fine screening applications. By Munesu Shoko.

The new Lokotrack ST2.3 mobile scalping screen is the most compact mobile screener with wide screen and aggressive stroke.

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| May/June 2022 | Vol. 1 Issue 3 | www.quarryingafrica.com

17 t

Weighing in at 17 t, the machine comes with a 3 m long x 1,5 m wide screen box

4,6 m²

Despite its compact build, the Lokotrack ST2.3 punches above its weight with a 4,6 m² screening area, said to be the widest in this size class

13 mm

An aggressive stroke up to 13 mm with 5G acceleration results in a high screening performance

KEY POINTS The Lokotrack ST2.3 sets new standards in versatility with its ability to process various feed materials across primary scalping and fine screening applications It can be used as a standalone unit or as part of a multi-stage crushing and screening process The machine is designed to process a range of materials, from topsoil and recycled concrete waste, to road base material and fine aggregates. It can also be deployed in commodities such as diamonds.

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Traditionally, aggregate producers and mines have always used finishing screens to size their final product. In the past five years, we have seen the trend shifting to using scalping screens to perform this function.

Its versatility is enhanced by the various screen media options, including grizzly, punch plate, finger grizzly, piano wire and wire mesh

Francois Marais, director sales and marketing at Pilot Crushtec.

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5 m³ The Lokotrack ST2.3 has a 1,2-m wide feeder and a hopper capacity of 5 m³

hile scalping screens have long been a prominent fixture in aggregate processing plants, they have always been located early in the flowsheet for ‘scalping’ oversized material for further processing, explains Francois Marais, sales and marketing director at Pilot Crushtec.

However, due to their continued evolution in recent years, scalping screens are gaining prominence in both heavy duty scalping and fine screening applications. Their adaptability speaks in particular directly to contractors who are increasingly on the lookout for versatile solutions that can be deployed across various processes and applications.

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SCALPING SCREEN 400 mm

Where a traditional screen accepts a 100 mm feed size, for example, a scalping screen can take up to 400 mm size material

This mobile screener can be used as a standalone unit or as part of multi-stage crushing and screening process.

Contractors know that every jobsite is from the feed, or they can do fine screening. different. However, they are also aware that The Lokotrack ST2.3 scalping screen is a multithey don’t have the luxury of purchasing use scalping screen perfectly suited to heavy specific pieces of equipment to match the duty scalping, fine screening and recycling. needs of every project. With a growing The machine is designed to process requirement to do more with less, a range of materials, from topsoil they can take advantage of and recycled concrete waste, to the Lokotrack ST2.3 scalping road base material and fine screen’s versatility, which aggregates. It can also be allows it to be adapted deployed in commodities such 8ℓ and to deliver the desired as diamonds.

Powered by a CAT C3.6 diesel results on a broad range of “The machine is versatile in engine producing 55 kW of power, applications. terms of who can use it, where the machine consumes about 8ℓ “Traditionally, aggregate they can use it and in what of fuel per hour, translating into lower total cost of operation producers and mines have applications they can use it. always used finishing screens For that reason, we believe that to size their final product. In it’s going to be a popular product the past five years, we have seen in the market, especially for entry the trend shifting to using scalping level and mid-range contractors, as screens to perform this function,” well as junior miners doing exploration says Marais. “The major difference between work, for example,” says Marais. a traditional screen and a scalping screen is It can be used as a standalone unit or as that the later can take a much bigger feed part of a multi-stage crushing and screening size than the conventional screen. Where a process. Its versatility is enhanced by the various traditional screen accepts a 100 mm feed size, screen media options, including grizzly, punch for example, a scalping screen can take up to plate, finger grizzly, piano wire and wire mesh.

400 mm size material.”

“Pilot Crushtec supports all these various A key benefit of scalping screens, adds Marais, media types. We also have some innovative is their versatility. They can be used as initial ones such as heavy-duty fingers or forged sizers to remove oversize pieces of material tynes,” adds Marais.

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| May/June 2022 | Vol. 1 Issue 3 | www.quarryingafrica.com

13-25 degrees

The screen comes with a variable inclination on the screen box, so depending on application, operators can change the angle of screening from 13 to 25 degrees

The ST2.3 can be easily transported in one piece between sites.

The set-up is quick and easy with hydraulic functions and visual indicators.

Key specs

the conveyor. The fines and mid-size belts are Weighing in at 17 tonnes (t), the machine comes both 650 mm wide, with adjustable heights with a 3 m long x 1,5 m wide screen box. Despite and speeds to suit different applications,” its compact build, the Lokotrack ST2.3 punches says Marais. above its weight with a 4,6 m² screening Amid record high fuel prices, fleet area, said to be the widest in this size owners will also benefit from class. This is complemented by an the machine’s fuel efficiency. aggressive stroke up to 13 mm Powered by a CAT C3.6 diesel with 5G acceleration, resulting in engine producing 55 kW a high screening performance. of power, the machine 1,2 m “There is also a variable consumes as few as eight The Lokotrack ST2.3 comes with inclination on the screen box, litres of fuel per hour, a 1,2 m wide oversize conveyor, so depending on application, translating into lower total which is pretty common in large operators can change the cost of operation. sized scalpers angle of screening from 13 to 25 Ease of transportation degrees,” says Marais.

Contract crushing is a nomadic The Lokotrack ST2.3 is venture by its nature, which often equipped with a 1,2 m-wide belt calls for moving of machines from feeder and a hopper capacity of one site to the other. With that in mind, 5 m³, which is considered to be groundMetso Outotec paid particular attention to ease breaking for a machine of its size. The machine of transportation during the development of the also comes with a 1,2 m wide oversize conveyor, Lokotrack ST2.3 scalping screen. which is pretty common in large sized scalpers, “With its compact dimensions (11 m long x making the Lokotrack ST2.3 more attractive, 2,8 m high x 2,2 m wide) and optimised weight especially in applications with large-sized (17 000 kg), the machine can be moved from material. one site to another using a standard trailer, “Another key feature of this machine is the with no need for abnormal load permits, thus impact bed located at the discharge point helping contractors cut back on transportation of the screen, which is not common for most costs,” concludes Marais. a screens. This results in a longer lifespan for

May/June 2022 | Vol. 1 Issue 3 | www.quarryingafrica.com |

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WIDE-BODY DUMP TRUCK

MOVING MORE FOR LESS

T

SANY’s wide body trucks are already at work in more than 20 countries, including leading mining destinations in southern Africa, such as the DRC, South Africa, Zambia and Zimbabwe.

As quarries and mines seek to improve their cost per tonne (t), SANY ’s wide-body dump truck concept – which has already taken root in China and several African markets – allows operations to load more for less. Having introduced the first 60-t model in 2018, the company is launching a new offering, the 70-t SKT105S. By Munesu Shoko.

he productivity of any quarry concept in 2018, with the launch of its 60-t largely hinges on the efficiency of model, the SKT90S. Since its debut, the truck its load and haul system. has been hard at work in more than 20 countries, Yet, loading and including leading mining destinations in hauling run-ofsouthern Africa, such as the DRC, South mine material represents Africa, Zambia and Zimbabwe. a significant component Following the success of the first of the total cost of opmodel, SANY is launching a larger eration. If properly imoffering, the SKT105S wide-body R90-million plemented, however, a dump truck. The new 70-t truck, load and haul optiexplains Thabo Lerumo, operations The company keeps a huge stockholding of about R90misation programme manager of Sany Rental at SANY million’s worth of parts can identify significant Southern Africa, is an upgrade of opportunities for operthe existing SKT90S. ational improvement.

Key features To help quarries Built after two years of research and and mines boost their development, the SKT105S comes with productivity at a lower cost of a range of feature upgrades. One of the operation, SANY Southern Africa major talking points is the hydro-pneumatic first introduced its wide-body dump truck

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| May/June 2022 | Vol. 1 Issue 3 | www.quarryingafrica.com

70 t

The new SKT105S has a 70-t loading capacity

2018

SANY first introduced the wide-body truck concept in 2018 with the launch of the 60-t SKT90S

The new 70-t SKT105S is an upgrade of the existing SKT90S.

Key specs Model

SKT105S

Loading capacity

70 t

Engine

Weichai WP13G530E310

Power

390 kW

Torque

2 300 Nm

Transmission

Allison 4800RS_PR (Automatic)

KEY POINTS SANY Southern Africa has launched its 70-t SKT105S wide-body dump truck The SKT105S is an upgrade of the 60-t the SKT90S, which made its debut in 2018 The wide-body dump truck’s value proposition is the ability to move more tonnage at a fraction of the cost of running a comparable articulated dump truck or rigid dump truck The SKT105S is also available for outright purchase or rental

suspensions are applied on both front and rear axles.

With leaf spring, the ride comfort is not as great because of the inter-leaf friction between each leaf. Over time, the springs tend to lose shape and can sag. When the sag is uneven, it can alter

the cross weight of the vehicle which can affect the handling slightly. This can also change the axle-to-mount angle.

According to Lerumo, the hydro-pneumatic suspension system improves comfort and productivity. The suspension features sound shock-absorbing and damping capabilities to improve the load application and prolong the lifetime of the frame.

“Comfort, productivity and profitability are among the most important qualities customers request from their machines today,” he says.

“The comfort of the suspension system is critical in meeting the vehicle’s daily permissible vibration exposure to the driver. The less vibration the driver feels, the more comfortable the ride is and, therefore, the longer the driver is allowed to work.”

Why wide-body dump truck?

The wide-body dump truck’s value proposition is the ability to move more tonnage at a fraction of the cost of running a comparable articulated dump truck (ADT) or rigid dump truck (RDT).

“To provide context, the SKT105S comes at less capital cost and rental rate than a 40-t ADT. However, the SKT105S wide-body dump truck has a 70-t loading capacity, almost double that of the 40-t ADT, yet its fuel consumption is much lower than that of the ADT. This is a compelling value proposition for mines and quarries seeking to increase their production at lower operating costs,” says Lerumo.

However, Lerumo is quick to point out that the

May/June 2022 | Vol. 1 Issue 3 | www.quarryingafrica.com |

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WIDE-BODY DUMP TRUCK

Built after two years of research and development, the SKT105S comes with a range of feature upgrades.

wide-body concept is not necessarily suited for machines immediately to execute urgent all project conditions. Given that it adopts the contractual needs,” he says. same design approach as the traditional RDT, it The high inventory levels are complemented therefore thrives on well-maintained roads. by recent investments in SANY Southern From a running cost point of view, the Africa’s operations to better support dealers SKT105S is a better cost-effective solution than across the region. The company commissioned the larger, conventional dump trucks. a 40 000 m² machine storage yard in For example, the truck uses the Boksburg, South Africa, in 2020. same type of tyres (16.00R25) Lerumo tells Quarrying Africa that as construction-type tipper the company also keeps a huge trucks, which cost far less than stockholding of about R90those of a comparable ADT million’s worth of parts, which 40 000 m² or RDT. The tyres are also is set to be increased to readily available from various R270-million in the next year.

In 2020, SANY Southern Africa commissioned a 40 000 m² retailers.

In addition, SANY offers machine storage yard in a wide range of equipment Boksburg, South Africa Availability and support from one stable, from Another major advantage of excavators and wheel loaders going the SANY wide-body to graders and rollers, making dump truck route is that the the company a one-stop shop company always keeps enough for earthmoving and haul road stock. This is critical, especially given maintenance tasks on site. This allows the current long lead times that customers customers to have a single point of contact for have to put up with when buying their missionall their load and haul equipment needs. critical equipment.

“The SKT105S is also available for outright “One of the main advantages of keeping purchase or rental. Our rental facility gives high stock levels is that we can ensure that customers the opportunity to evaluate fulfilment times are always met within the the truck before they commit to outright timeframe that customers want their machines. purchasing. In fact, two customers just This is mostly beneficial for the contract mining confirmed the delivery of the first batch of fraternity, where customers often need their SKT105S trucks,” concludes Lerumo. a

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| May/June 2022 | Vol. 1 Issue 3 | www.quarryingafrica.com

CRUSHING The J35R compact jaw crusher is the perfect solution for projects with small footprints but big requirements.

Key specs Model

McCloskey J35R

Production capacity

250-300 tph

Maximum feed size

400 mm

Weight

26 500 kg

Transport Width

2,4 m

Engine

Volvo (162 kW)

40 mm The J35R has a minimum closed side setting of 40 mm

WHEN SIZE MATTERS

Kemach Equipment has introduced the new McCloskey J35R to the local market. The compact jaw crusher punches above its weight with the ability to meet big crushing requirements at sites where space is at a premium. It fits the bill for small-scale recycling contractors seeking a solution for crushing both abrasive and non-abrasive materials, writes Munesu Shoko.

S

uited particularly to construction, demolition recycling, asphalt recycling and aggregates, the J35R compact jaw crusher is the perfect solution for projects with small footprints but big requirements, states Bradley Karolus, sales specialist at Kemach Equipment.

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Speaking to Quarrying Africa, Karolus says the J35R addresses a special need in the market, especially in the recycling industry where impact crushers have traditionally been the only available solution for small-scale projects. The downside is that impact crushers are better suited to non-abrasive material, which makes it difficult for contractors

| May/June 2022 | Vol. 1 Issue 3 | www.quarryingafrica.com

26,5 t

Weighing in at 26,5 t, the J35R is said to be one of the first jaw crushers of its weight and size in the market with a large opening of 900 × 600 mm

2,5 m

Less than 2,5 m wide, the crusher can be transported easily from site to site

Kemach Equipment has brought in the first J35 unit in the country.

KEY POINTS Suited particularly to construction, demolition recycling, asphalt recycling and aggregates, the J35R compact jaw crusher is the perfect solution for projects with small footprints but big requirements The J35R offers the best of both worlds – it allows contractors to move between abrasive and non-abrasive jobs using one machine The machine is said to be the only jaw of this size to have the recirculating option Powered by a Volvo diesel engine producing 162 kW of power, the machine is tipped to be a hit with customers in the local market due to its lower fuel consumption

to deploy the same machines to crush abrasive material.

“With impactors, contractors are limited to less wearing material such as coal and rubble.

It becomes difficult when they win contracts to crush high wearing material such as blue rock and chrome slag. These materials are high wearing because of their abrasive nature and are therefore suited to a jaw crusher. From a cost perspective, deploying an impact crusher in abrasive applications is not a good idea, because your cost per tonne will increase,” explains Karolus.

The J35R offers the best of both worlds – it

“

Combining the productivity of the J35R with the versatility of a full screening and recirculating system allows operators to produce a crushed and screened final product with just one machine.

Bradley Karolus, sales specialist at Kemach Equipment

May/June 2022 | Vol. 1 Issue 3 | www.quarryingafrica.com |

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CRUSHING

Powered by a Volvo diesel engine producing 162 kW of power, the machine is tipped to be a hit with customers in the local market due to its lower fuel consumption.

allows contractors to move between abrasive and non-abrasive jobs using one machine.

contractors to produce G5 material without having to close the CSS beyond its design limits.

Features and benefits “Traditionally, contractors have had to close Weighing in at 26,5 t and less than 2,5 m the jaw’s CSS beyond its tolerance levels to wide, the J35R is said to be one of the first jaw enable them to produce G5 material, which has crushers of its weight and size in the market proved detrimental to the life of the machine,” with a large opening of 900 × 600 mm. The jaw he says. takes a maximum feed size of 400 mm, with a In addition, because of the post screen, minimum closed side setting (CSS) of 40 mm. contractors can now feed a vertical shaft It has a production capacity of between impact (VSI) crusher directly from 250 and 300 tph. a jaw. Previously, this was not The J35R can easily crush achievable as the topsize from a and move at the same time, jaw is too big to report directly ensuring maximum mobility and to a VSI before further productivity on project sites. A reduction. The post screen 400 mm two-speed system is selectable allows operators to control at the control panel which the size of the product The jaw takes a maximum feed enables a smooth start/stop. that goes into the VSI. This size of 400 mm The machine is said to be reduces the number of the only jaw of this size to machines required in the have the recirculating option. train, translating into lower The recirculation conveyor allows wear and running costs. operators to produce a crushed Powered by a Volvo diesel and screened final product using only engine producing 162 kW of the one machine. power, the machine is tipped to be a “Combining the productivity of the J35R hit with customers in the local market due to with the versatility of a full screening and its lower fuel consumption. The patent ECO recirculating system allows operators to setting brings fuel burn to below 10 litres per produce a crushed and screened final product hour, depending on application. with just one machine,” he says. “This design Less than 2,5 m wide, the crusher can be approach makes the process cost-effective by transported easily from site to site. Because it removing the need for two separate machines.” weighs less than 30 t, no special permits are Another key talking point is the post screen, required to transport it between jobsites. This is which offers a number of benefits. With a 55 particularly beneficial for contractors who have mm mesh, for example, the post screen allows to move from one job to the other. a

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| May/June 2022 | Vol. 1 Issue 3 | www.quarryingafrica.com

PERSPECTIVE – CONVEYORS A well-designed conveyor system controls the maximum load at the highest achievable volume, with the safest possible work environment.

THE ECONOMICS OF WORKPLACE SAFETY Conveyor safety is not a modern trend bred by government regulation; it’s a common-sense idea as old as the first conveyor design. In the modern age, safety is a key factor in worker protection, reduced insurance rates and a lower total cost of operation. By R. Todd Swinderman, CEO Emeritus, Martin Engineering.

T

here are several hurdles to the installation of safety equipment, the biggest of which is the near-universal use of the low bid process.

When companies buy on price (low bid) the benefits are short-lived and costs typically increase over time. In contrast, when purchases are made based on lowest long-term cost (life cycle cost), benefits usually continue to accrue and costs go down,

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resulting in a net savings over time.

Organisations that embrace safety show significant performance advantages over the competition.

The proof is reflected in reduced injuries and greater productivity, along with above industry average financial returns and higher share prices.

Safer and more reliable equipment is easier to service, has a longer life and is less expensive to maintain.

Justifying safety investments

| May/June 2022 | Vol. 1 Issue 3 | www.quarryingafrica.com

20

By choosing the lowest-priced bid to meet the minimum safety requirements, the short-term expenditure ends up costing considerably more over the 20-year lifecycle

50%

By spending US$750 000 more to exceed the minimum safety and design requirements and reduce the accident rates by 50%, the annual projected cost of accidents drops from US$140 813 to US$70 407

“

Justifying safety investments is greatly enhanced by quantifying what most financial managers refer to as intangible costs, i.e., injuries, lost labour, insurance, morale and legal settlements, among others. However, managers and accountants have been trained to think about saving direct costs to justify investments.

R. Todd Swinderman, CEO Emeritus, Martin Engineering.

KEY POINTS When companies buy on price (low bid) the benefits are short-lived and costs typically increase over time Safer and more reliable equipment is easier to service, has a longer life and is less expensive to maintain

is greatly enhanced by quantifying what most financial managers refer to as “intangible costs”, i.e., injuries, lost labour, insurance, morale and legal settlements, among others. However, managers and accountants have been trained to think about saving direct costs to justify investments.

When conveyors do not operate efficiently, they have unplanned stoppages, release large quantities of fugitive materials and require more maintenance. Emergency breakdowns, cleaning of excessive spillage and reactive maintenance all contribute to an unsafe workplace.

Safety pays

Numerous case studies revealing the positive relationships between safety and productivity are backed up by organisations that gather global statistics on accidents and incidents. The simple

When conveyors do not operate efficiently, they have unplanned stoppages, release large quantities of fugitive materials and require more maintenance Emergency breakdowns, cleaning of excessive spillage and reactive maintenance all contribute to an unsafe workplace

formula for return on investment (dividing savings by cost) does not capture the potential savings from safety investments. Several organisations provide detailed and regional statistics on the cost of accidents.

Lacking specific historical data, managers can turn to numerous reliable sources that provide the probability of incidents that can be used to estimate tangible and intangible future costs.

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PERSPECTIVE – CONVEYORS

Figure 1: Life cycle costs.

Figure 2: Regional statistics on costs of accidents.

Figure 3: Accident rates per 100 000 industrial workers per year.

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| May/June 2022 | Vol. 1 Issue 3 | www.quarryingafrica.com

Figure 4: Estimated total annual costs for all accidents.

Figure 5: Annual accident costs for years 1 to 20.

The financial technique used to compare options is called a “net present value” (NPV) analysis. NPV compares different investment options with varying costs and savings (cash flows) over time, discounting them by the company’s cost of money.

For example, an internal risk analysis shows a facility has 30 workers exposed to conveyor hazards. The estimated probability of the different classes of accidents (fatal, lost time and first aid) is multiplied by the cost of these accidents to reveal what could be invested to reduce the incident rate by half.

Assuming the life of the conveyor is 20 years, and the cost of money (discount rate) is 5%, the available additional investment would be about US$750 000 more in design time to accomplish the 50% improvement in safety. By choosing the lowest-priced bid to meet the minimum safety

requirements, the short-term expenditure ends up costing considerably more over the 20-year lifecycle.

By spending US$750 000 more to exceed the minimum safety and design requirements and reduce the accident rates by 50%, the annual projected cost of accidents drops from US$140 813 to US$70 407.

Measured in today’s dollars – including the additional investment of US$750 000 – the projected savings over the 20-year term at 5% are about US$1,2-million by investing more upfront.

If, after further analysis, the savings are found to be less – perhaps only a 25% reduction in the cost of accidents – the upfront investment is still justified over the long term. Even though it takes a little more effort to collect data and do a financial analysis, in the end, NPV consistently proves that safety does indeed pay. a | May/June 2022 | Vol. 1 Issue 3 | www.quarryingafrica.com

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SUPPLY CHAIN NEWS

Weir Minerals integrates key brands in Mudflo pump

Grindex Mega claims title as dewatering workhorse

82 m The Mudflo 200 pump is capable of pumping between 150 and 1 200 m³/h, up to a head of 82 m

The Multiflo Mudflo pump has been engineered for abrasive applications.

Integrating its growing range of products into engineered-to-order (ETO) solutions is increasingly a way of life at Weir Minerals. The recent launch of its dredge-mounted Multiflo Mudflo pump shows how effective this approach can be, and how much it can contribute to customers’ bottom lines.

This dredge/excavator-mounted, mud-pumping innovation was launched last year, after being developed in response to a challenge which a customer faced, says Marnus Koorts, GM pump products at Weir Minerals Africa.

It is a heavy duty, hydraulic, submersible slurry pump designed for abrasive applications and large particle handling. Its application is primarily in reprocessing and relocating tailings ponds, maintaining water retention dams and managing slimes and sludge ponds.

“The Multiflo Mudflo pump successfully combines elements of the Warman MGS submersible slurry pump-end, and a custom Multiflodesigned bearing assembly coupled to a hydraulic motor,” Koorts says.

“Another key ingredient is the pairing of twin Multiflo CB33 hydraulic cutters with Weir ESCO excavation teeth.”

The cutters mechanically agitate the settled solids, allowing abrasive and highly charged slurries and

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mud to be efficiently pumped. He emphasises that the components making up the Multiflo Mudflo pump are drawn from Weir Minerals proven brands and are carefully combined to produce an integrated solution that saves customers time and money. It also reduces environmental impact, by avoiding the costly and energyintensive process of excavating and trucking the material off site.

“The pump design includes Weir Minerals’ Ultrachrome A05 chrome alloy casting for high wear resistance,” he says. “There is also a suction strainer to prevent excessively large particles clogging the pump.”

This ensures that the unit delivers optimal uptime alongside high performance levels: the Mudflo 200 pump is capable of pumping between 150 m³/h and 1 200 m³/h, up to a head of 82 m. The pump can handle a maximum particle size of 80 mm, and a maximum liquid temperature of 35°C. “While our integration of products has grown organically over the years, it has become more systematic and deliberate as our product range has grown and become more diverse,” says Koorts. “The way we have developed this solution shows the progress in recent years toward integrating our product lines to add value to our offerings.” a

Known as the workhorse of pump dewatering, the Grindex Mega pump is ideal for pumping large quantities of dirty water and is available in two configurations – the Mega N for normal head applications and the Mega H for high head applications.

Integrated Pump Technology is the official Grindex pump distributor for southern Africa.

Integrated Pump Technology is the official Grindex pump distributor for southern African and the Grindex Mega is available through its strategically situated network of distributors which cover South Africa as well as Zambia and the DRC. Easy to install and simple to operate, the plug-and-play Grindex Mega pump is available in two configurations, the Mega N for normal head applications and the Mega H for those that require very high head pumping such as deep excavations found in open pit operations as well as underground mines.

Manufactured from cast iron, the Grindex Mega pump is engineered for use in heavy duty arduous applications including those with corrosive liquids such as salt water or where the pH levels is between 6 to 13. Zinc anodes are available for extra protection. The pump has a flow rate of 150 litres per second at a maximum head of 200 m. a

| May/June 2022 | Vol. 1 Issue 3 | www.quarryingafrica.com

Collaboration agreements key to Booyco PDS global growth Jess Kindler to leave Epiroc

The core function of PDS and CPS technology is detecting and avoiding collisions.

Booyco Electronics CEO Anton Lourens says he is heartened by the growing acceptance in the international mining sector that there is the need to understand what any particular technology does and does not do prior to making decisions to implement PDS. Strategically, Booyco Electronics broadened its global reach over the last few years through collaboration agreements with selected technology integrators thus creating the optimal channel to customers in regions where the company does not have its own infrastructure.

“Our technology partners understand the safety and other benefits of Booyco Electronics’ PDS solutions. Most importantly they bring their insights into the local conditions in which our equipment can be applied, giving mining operations essentially the best of both worlds,” he says. “Through this approach we have been making inroads and expect to continue to do so.”

The company now has collaborations with several technology specialists worldwide including Insucam, Ramjack, RCT, Tecwise and Wenco.

Lourens says that when considering the implementation of a PDS solution the first step is conducting a detailed risk assessment, irrespective of whether it is an underground or

open pit operation; he is quick to caution, however, that it is especially risky for an operation to rush into a PDS installation after a safety incident that has led to a partial or total mine shutdown, whether that be for regulatory or operational reasons. “Being hasty can be counter-productive, and for a PDS installation to be successful it is essential that it meets the specifications identified in the risk assessment,” he says.

“This calls for a collaborative project approach, with all stakeholders participating in it, including the customer, the PDS supplier and a competent systems integrator. This should be for both the selection and implementation of a PDS or CPS solution,” he says.

“This early engagement should include mine management and personnel, trainers, OEMS, suppliers and integrators. They all need to understand why the PDS solution is being considered and the implications and benefits of this.”

Commenting on stakeholders, Lourens says that TMM operators are key participants in the process, and during the implementation stage it is critical that equipment installation teams engage one-on-one with operators, addressing technical questions. Training of operators is also vital to ensure that they understand how the PDS equipment works and how to care for it. a

Jess Kindler, President of Epiroc’s Parts & Services division.

Jess Kindler, President of Epiroc’s Parts & Services division and member of Group Management, has decided to leave the group for a position at a private company based in the United States.

“Jess has made significant contributions to the development and successful growth of Epiroc, since 2016 as President of our parts and services division,” says Helena Hedblom, Epiroc’s President and CEO. “He will move home to the United States for a new opportunity, and I wish him all the best.”

Jess Kindler joined the group in 2005 and will continue to lead the Parts & Services division until further notice. He will leave the group no later than January 2023.

May/June 2022 | Vol. 1 Issue 3 | www.quarryingafrica.com |

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SUPPLY CHAIN NEWS

Greater efficiency with new Volvo L350H wheel loader Built to take on the toughest of jobs, the upgraded L350H wheel loader from Volvo Construction Equipment (Volvo CE) arrives on the back of decades of innovation – to further enhance the profitability of customers’ operations.

Complete with a host of upgrades, the Volvo L350H wheel loader is ready to tackle a range of applications from mining and quarrying to heavy infrastructure – but now with greater productivity and fuel efficiency, all with lower service costs.

The flagship of the Volvo wheel loader range, the L350H comes prepared for heavy-duty applications as standard from the factory thanks to the proven Z-bar lifting arm with double sealing on each of the pins, and strong frame structure, which is joined by a reinforced upper centre hinge and new Volvo axles. Whether it be log loading, rock loading, rehandling, block handling or slag handling, Volvo CE has the specialised package (of machine features, tyres and attachments)

10% A more responsive hydraulics system, featuring new lift and tilt cylinders, and an increased hydraulic working pressure allow for 10% faster work cycles and higher productivity

needed to achieve maximum performance.

This heavy-duty upgrade is built on the success of its forerunners – a proud heritage which dates back to the first L320 wheel loader in 1985 – with a few notable improvements. A more responsive hydraulics system, featuring new lift and tilt cylinders, and an increased hydraulic working pressure allow for 10% faster work cycles and higher productivity.

Meanwhile, the upgraded driveline features new Volvo axles and an all-

new Volvo transmission which enables the third generation OptiShift to be equipped as standard. Already found on Volvo L150H-L260H wheel loaders, this proven technology integrates the Reverse by Braking function and the lock-up function in transmission to boost fuel efficiency by up to 15%.

Efficiency is further enhanced by an optimised gear shifting ratio and by the new converter, which delivers higher outputs, resulting in up to 22% more tractive force depending on selected gear and machine speed. a

First ever Liebherr TA 230 ADT in Africa Zimbabwe-based mining contractor, Orca Group, has taken delivery of the very first Liebherr TA 230 Litronic articulated dump truck (ADT) in Africa. The new ADT – which plugs the gap in the company’s earthmoving product range – made its local debut at an Open Day held on 24 June 2022.

Orca will deploy its ADT in an underground application at the Freda Rebecca Gold Mine in Bindura, Zimbabwe, hauling ore from the underground tunnels to the overland crushers.

This, says Gordon Watson, MD of Orca, will be a true test for the new ADT. “We are very excited to be the first recipient of this groundbreaking machine in Africa,” says Watson. “We will deploy it in a taxing underground application, which we believe will test the machine to its limits.”

Dieter Schmid, MD of Liebherr-Africa, says the new ADT closes a crucial gap in the company’s wide earthmoving equipment range.

“With the addition of the TA 230 Litronic, we have become a full-liner in the earthmoving area. The ADT is the last piece of the puzzle, making us a one-stop shop for all our customers’ earthmoving equipment needs,” says Schmid.

Tendayi Kudumba, GM: Earthmoving at Liebherr-Africa, says the new 30-tonne (t) class ADT is ideally suited for quarrying, coal mining and large infrastructure projects. Thanks to its optimal structure gauge, the TA 230 can also be deployed in special applications such as tunnel construction and underground mining. a

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30 t The new 30-t class ADT is ideally suited for quarrying, coal mining and large infrastructure projects

Tendayi Kudumba, GM: Earthmoving at Liebherr-Africa (far left), hands over the first TA 230 in Africa to Gordon Watson, MD of Orca (middle), with Ian Duncan, MD of DieselPro Services (LiebherrAfrica’s Zimbabwean dealer) looking on.

| May/June 2022 | Vol. 1 Issue 3 | www.quarryingafrica.com

Level 1 B-BBEE is big step in FLSmidth’s transformation journey Trafo’s flexibility on show at Electra Mining

Thabisa Mhlatyana, despatch administrator, Manufacturing & Warehousing and Luyanda Maqubela, cost engineer, Manufacturing & Warehousing at FLSmidth.

Embracing diversity, inclusion and engagement, FLSmidth’s South African business has for years enhanced productivity through transformation. These efforts were recognised recently when it earned Level 1 Broad-Based Black Economic Empowerment (B-BBEE) status. The company sees the accomplishment as an important ‘licence to operate’.

Deon de Kock, FLSmidth President for Sub-Saharan Africa, Middle East and South Asia, emphasises that diversity, inclusion and engagement are imperatives for good business.

“As we drive success through productivity enhancement, we draw on the best available human and technological resources,” says De Kock. “This includes not just our staff but all stakeholders in our supply chain.”

Investing in its talent pipeline was particularly important in promoting diversity, he says. This has included skills development through apprenticeships, learnerships, scholarships and graduate programmes. The success of these candidates has ensured solid progress in employment equity, as one B-BBEE element within its integrated approach.

“B-BBEE is not a once-a-year event for FLSmidth, but rather a long-term business strategy,” says Estelle Steytler, head of People and Organisational Development and

Transformation at FLSmidth. Steytler highlighted the important role of dedicated champions within the business to implement B-BBEE policy.

“Each of these champions focuses on a particular aspect of B-BBEE,” she says. “These include management control, skills development, ownership, socio-economic development, and enterprise and supplier development.”

Structures have also been set up to support the FLSmidth board, keeping transformation as a top priority on the agenda. A social and ethics committee reports to the board. This committee in turn receives input from an employment equity and skills development committee, an enterprise and supplier development committee, and a corporate social responsibility committee.

“It has always been our aim to deliver transformation through a focus on shared value, with clear aims and intent,” she says.

She also emphasises the success in building the talent pipeline. Many university students supported by FLSmidth bursaries are now employed in roles such as mechanical engineers, technology specialists and HR experts. De Kock points out the vital importance of taking young graduates and trainees into the business. a

Given the varying nature of operating conditions from one mine to another, Trafo Power Solutions, a specialist in the design and supply of drytype transformers, will use Electra Mining Africa 2022 to demonstrate its flexibility and ability to tailor its solutions to meet specific site and customer needs.

“Leveraging many years of experience in the mining industry, pretty much across all commodities, we have comprehended that each mine is different and has its own set of challenges,” explains David Claassen, MD of Trafo Power Solutions. “A onesize-fits-all approach is therefore out of the question, which is why most of our products are custom designed and manufactured to specific site conditions.”

Because they use air as a medium of cooling, dry-type transformers are typically installed in indoor environments, however, Trafo Power Solutions has a wealth of experience in supplying dry type transformers for outdoor applications The design of the enclosure is therefore critical to withstand the common harsh conditions associated with high dust and moisture levels. Despite the restrictive nature of enclosures, Trafo Power Solutions’ custom design capability guarantees enough ventilation, while allowing for necessary levels of ingress protection to keep dust and moisture at bay. a

May/June 2022 | Vol. 1 Issue 3 | www.quarryingafrica.com |

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SUPPLY CHAIN NEWS

Blasting’s role in making mining more sustainable

Mato seeks to expand belt cleaning footprint

Mato Products will unveil a new range of belt cleaners at Electra Mining Africa 2022.

Omnia Group company BME’s digital tools can make mining more efficient and less carbon intensive.

Technology in blasting – alongside advanced low carbon emission emulsion explosives – are helping pave the way for mines on their sustainability journey.

“The digital age has given us the opportunity to leverage the quality of our people, products and service – to optimise blast technology,” says BME MD Ralf Hennecke. “Building on the flexibility and accuracy of electronic detonation, our digital tools can make mining more efficient and less carbon intensive.”

By collaborating with customers and technology partners, BME has developed solutions that can enhance output and are easily integrated – both between BME’s digital products and externally. Hennecke emphasised that software platform integration was key to ensuring that innovative digital tools could operate seamlessly with a mine’s existing systems.

An innovation that has received global acclaim is BME’s electronic detonation system, AXXIS. Developed by an in-house team of specialists, AXXIS improves the quality of blasts and mine productivity.

“The entire system was designed in South Africa and built by our own engineering department,” says Tinus Brits, global product manager for AXXIS. “All the support and maintenance on the system is conducted by our dedicated in-house technicians.”

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Applied in conjunction with BME’s Blastmap blast planning software, AXXIS demonstrates the value of product integration. Complex blast designs can be easily and quickly transferred from the Blastmap planning platform to the AXXIS initiation platform. Brits notes that Blastmap can also export to third party initiation systems that a mining customer might already be using.

Among the capabilities that BME has brought to the mining sector are longer blasting windows to allow for larger and more productive blasts.

“The increased firing window of AXXIS Titanium – the latest generation of the AXXIS system – gives mines the opportunity to conduct larger blasts,” he says. They can also design more complex blasts.

The quality of these blasts ensures better fragmentation, so that less energy is consumed in downstream stages like loading, hauling, crushing and milling. Less energy converts directly to lower carbon emissions when coal- or diesel-fired electricity is used. Larger blasts also mean fewer mine stoppages, allowing a more streamlined mining process.

“Safety remains a key focus in mining, and a safe mine is a productive mine,” he says. “Our digital initiation systems innovate constantly to raise the level of safety in blasting – such as the dual basis of safety in our latest AXXIS Titanium system.” a

Renowned for its belt lacing and clip fasteners for conveyor belts, Mato’s immediate growth strategy entails the expansion of both the range and the supply footprint of its belt cleaning systems. To drive the plan home, the company’s exhibit at Electra Mining Africa 2022 will focus particularly on belt cleaners.

Having been founded with a specific mandate to manufacture and supply mechanical conveyor belt fastening systems, Mato Products, a Multotec Group company, has become a household name in belt lacing equipment and clip fasteners. The two product ranges remain the company’s bread and butter, confirms managing director Benjamin Sibanda.

However, when Sibanda took the reins at Mato, initially as general manager back in 2015, one of his immediate tasks was to diversify the company’s offering, which prompted the move into belt cleaning systems.

To mark its first foray into this market, the company displayed its first units at Electra Mining Africa 2016.

In 2019, Mato landed its first major contract to supply and maintain belt cleaners for a leading colliery in the South African coal region of Emalahleni.

This was immediately followed by another major contract, this time at a Botswana colliery for both the plant and underground operations. Since then, the company’s belt cleaning range has gained significant momentum in the market, particularly in the coal sector.

Going forward, however, the focus is to further grow the supply footprint into other commodities beyond the mainstay market of coal. a

| May/June 2022 | Vol. 1 Issue 3 | www.quarryingafrica.com

Kwatani casts the spotlight on innovation and digitalisation As mines continue to seek ways to improve efficiency and to reduce costs, leading vibrating equipment OEM Kwatani will use Electra Mining Africa 2022 to showcase its leadingedge multi-slope screening technology and the company’s advances in digitalisation.

While multi-slope screens – generally known as ‘banana’ screens – have been available since the 1980s and are therefore not necessarily new to the market, Kwatani has in recent years ushered in a whole new approach to the design of these screens, says CEO Kim Schoepflin.

“Traditionally, multi-slope screens have always been renowned for their high velocity,” she says. “While the high velocity translates into high capacity, the downside is the resultant screening inefficiency and the high wear rate of the panels, which in turn translates into high maintenance costs.”

At the top of these screens, explains Kwatani COO Kenny Mayhew-Ridgers, is usually a first slope with a deck angle of at least 34 degrees – allowing material velocities of over 4 m per second – curving down to end at about 10 degrees.

This traditional layout, however, is not always ideal for many operations today, as it calls for a much higher installation height. With a much flatter layout, the Kwatani design means that the installed height of the screen is far lower, translating into lower costs – both from a building and machine fabrication perspective.

“Banana screens have always been designed this way, and it became an industry norm,” says Mayhew-Ridgers. “Nobody really evaluated this traditional design, until recently when Kwatani, through its research and development, challenged the norm and adopted an innovative

Kwatani will showcase its advances in the digital space at Electra Mining Africa.

multi-slope design with great success.”

Kwatani can design its screens to perform efficiently at a lower building height and fit into existing screen infrastructure. The lower physical height of the screen also impacts the capital cost of complementary equipment such as pumps. “Because you have to pump at lower heights, you can therefore acquire smaller pumps, which means that the energy footprint is also much lower,” Schoepflin adds.

Apart from its leading-edge multi-slope screen design, Kwatani will also showcase its advances in the digital space. Digital

technologies, says Schoepflin, have the potential to unlock new ways of managing variability and enhancing productivity.

The miniature version of the Kwatani multi-slope screen to be displayed at Electra Mining Africa will therefore be digitally enabled.

“We approach digitalisation in two ways.

We believe that sensors are the starting point, as they are where data is created.

Embedding sensors in plants, which in turn churn out large volumes of data for analysis, is increasingly attainable,” says Mayhew-Ridgers. a

May/June 2022 | Vol. 1 Issue 3 | www.quarryingafrica.com |

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SUPPLY CHAIN NEWS

New Lokotrack LT200HXP increases capacity by up to 30%

30% Leveraging the machine’s two-deck pre-screen designed to reduce the amount of fine material that reaches the crushing process, contractors can expect up to 30% more material throughput

The Lokotrack LT200HPX mobile cone crusher is especially suitable for a secondary or tertiary crusher in a two or three stage crushing process.

Pilot Crushtec is launching Metso Outotec’s Lokotrack LT200HPX mobile cone crusher in southern Africa.

Leveraging the machine’s two-deck pre-screen designed to reduce the amount of fine material that reaches the crushing process, contractors can expect up to 30% more material throughput.

Ideal for secondary and tertiary hard rock crushing, the Lokotrack LT200HPX features the proven Metso Outotec Nordberg HP200 cone crusher unit, which is renowned for its high productivity, low operating costs and long service life. With over 10 000 units sold globally, the Nordberg HP200 has over the years established itself as Metso Outotec’s most popular cone crusher.

When designing the Lokotrack LT200HPX, Metso Outotec paid particular attention to increased productivity, which largely hinges on the machine’s two-deck pre-screen, as well as the wide feeding and production conveyors, resulting in up to 30% more capacity.

“In many instances, the crusher is fed with a high proportion of fine material, which needlessly passes through the crushing chamber, resulting in reduced throughput and increased wear and energy consumption. With the 1,2 mm

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x 1,8 m two-deck pre-screen, the fine material in the feed can bypass the crusher and go straight to the stockpile or further in the process. This not only increases overall output, but also decreases wear and packing in the crushing chamber and can enhance product quality,” explains Francois Marais, sales and marketing director at Pilot Crushtec.

The standard H12-10 main conveyor’s adjustable discharge height (2 900 mm / 3 900 mm) allows the LT200HPX to be combined easily with other machines in the train. It can also be lowered to ground level for easy maintenance.

Further optimisation of crushing results is achieved through Metso Outotec’s IC process control system.

The user interface enables singlebutton start and stop and features built-in troubleshooting as well as various parameter selections. It also allows for connection between all Lokotrack crushers and screens in the same process.

With efficiency in mind, the Lokotrack LT200HPX comes with a CAT engine and direct v-belt crusher drive, ensuring optimum fuel efficiency.

Direct drive for crusher with purposely designed gearbox and hydraulic clutch increases machine reliability. a

Metso Outotec collaborates with Dynamox Metso Outotec and Dynamox have entered into a global cooperation agreement on the usage of Dynamox’s condition monitoring platform in mining and aggregates processes.

Metso Outotec is offering the solution to its own installed equipment base; the partner agreement enables also third-party equipment monitoring, further strengthening the company’s digital scalability and solution flexibility.

“Dynamox is an important addition to Metso Outotec’s partner ecosystem and is complementing our goal of developing and providing easy-to-use and sustainable digital solutions to our customers. We also see significant opportunities for further development in the field of AI and analytics,” says Tuomas Martinkallio, vice president, Digital Services, Metso Outotec.

“The new technology will become a seamless part of the Metso Outotec Metrics solution. For example, screening customers use Metrics to obtain real-time condition monitoring data that can be used to continuously improve production efficiency and achieve maximum output,” states Jan Wirth, director, RTD and Engineering, Screening business line, Metso Outotec.

By combining Metso Outotec’s OEM

The new technology will become a seamless part of the Metso Outotec Metrics solution.

| May/June 2022 | Vol. 1 Issue 3 | www.quarryingafrica.com

Zest WEG boosts local supply chain Zest WEG progressively increased its level of local manufacturing over the past decade and now boasts six manufacturing sites – four in the Gauteng region and two in Cape Town.

A key aspect of this manufacturing drive has been the development of local suppliers by Zest WEG; an effort which has met with considerable success. “Building up our local supply chain is important, of course, in terms of meeting targets for black empowerment stipulated by the government and the mining industry, which is one of our main markets.

Having said this, local sourcing is a value that is built into WEG’s culture globally and is nothing new for us,” says Eduardo Werninghaus, newly appoint Group CEO of Zest WEG. Werninghaus notes that WEG started up in 1961 in the southern Brazilian state of Santa Catarina which was then very undeveloped with the local economy relying primarily

expertise with the digital solution offered by Dynamox, it is possible to provide customers with modern, easyto-install instrumentation that can be complemented with comprehensive value-added services in the customer’s value chain. When the innovative monitoring capability is combined with Metso Outotec’s Performance Centres’ remote monitoring services and global field service network, the company can further support customers in achieving reliable plant performance.

“We are delighted to collaborate with Metso Outotec for the customer benefit. For us, the strategic partnership is a significant recognition of the development of innovative and high-quality maintenance solutions that are different from those of other solution providers,” says Guillaume Barrault, CEO, Dynamox. a

Zest WEG Heidelberg facility for manufacturing E-houses.

on agriculture. “WEG really had no choice but to develop local suppliers, given the distance of its factory from Brazil’s main industrial centres. This programme met with such success – and made such economic sense – that it has now become the standard practice for WEG companies around the globe.”

Commenting on the benefits of local sourcing, Werninghaus says that it gives Zest WEG enhanced control over the production process and helps keep down costs. It also allows short delivery times, as there is less reliance on global markets for parts and componentry, a huge advantage currently given the constraints of the global supply chain. He adds that it has also made a major contribution to Zest WEG achieving its current Level 1 B-BBEE status.

Zest WEG gives considerable assistance to emerging companies that it brings into its supply chain, upgrading their skills so that they are able to produce to the demanding standards of the WEG Group. “We’re a very aggressive company when it comes to manufacturing and very focused on efficiency and productivity.

This same culture has been successfully instilled into our South

African operations, including our local suppliers,” he says.

In Gauteng Zest WEG has two transformer factories. One is in Wadeville and the other in Heidelberg.

Also in Gauteng, Zest WEG – through its WEG Automation division (previously Shaw Controls) – produces a wide range of electrical panels in Robertsham and E-Houses and other electrical enclosures in Heidelberg.

In Cape Town, the company has two production facilities, one producing engineered gensets and the other focused on panel production.

Discussing how far local manufacture has advanced, Werninghaus says that the transformers can have more than 90% local content and panels and E-Houses close to 70% depending on the specifications.

“It’s virtually impossible to get to 100 % local content on any of the product lines we manufacture in South Africa, as there will always be certain things that have to be imported due to technical and economic reasons,” he comments. “Nevertheless, we are constantly looking for opportunities to replace imported componentry with locally produced parts so our level of local content will certainly increase further with time.” a

May/June 2022 | Vol. 1 Issue 3 | www.quarryingafrica.com |

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DUST CONTROL

GUIDELINE FOR DUST CONTROL AT QUARRIES ASPASA has published a detailed guideline to help quarries deal with dust at their operations. In the meetings held with the regulator, the Department of Mineral Resources and Energy (DMRE), the surface mining association says it has become clear that dust is a problem that needs to be addressed. By Munesu Shoko.

T

CORPORATE PARTNERS

he document is an attempt to give some guidelines on what can be done at ASPASA member quarries to mitigate dust. Here are some of the important excerpts from the guideline: 1. What should a quarry/plant manager do?

First of all, forget the regulations and standards that you don’t really need to know to solve your problem.

Think about dust control in terms you understand.

Dust and spillage occur because the material in handling and processing systems leaks.

Plug the leaks and you will put more tonnes into trucks. When you start to think about controlling the process you are much more likely to come up with practical solutions that are easy to integrate into your operations.

2. Good process control is good dust control Good process control and good dust control are just two sides of the same coin. There are lots of ways to make more money by complying with regulations.

There are several examples where quarries have been paid to use waste products as dust suppressants – especially for roads. This allows the chemical company to avoid the higher cost of disposal.

If you don’t understand the relationship between process and pollution control, you are much more likely to make mistakes that will ultimately cost production and lose money. On common error is to spend as little as possible on the environment.

Don’t make the other common error, waiting until you get forced to comply. That’s a sure way to develop an adverse relationship with your neighbours and the state that will add penalties and fines to your list

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www.pilotcrushtec.com

www.rocktechnology.sandvik/en/

www.scania.com/za

www.sanysouthafrica.com

Good process control and good dust control are just two sides of the same coin.

of accomplishments. If you don’t solve the problem, the regulators will do it for you by forcing the plant to use control measures that are much more costly and cumbersome.

Instead of whining about environmental compliance, find ways to turn the ‘lemon’ of regulation into ‘lemonade’ of profits. Believe it or not, dust control measures are actually good for production.

For example, choke feeding a crusher not only maximises its productivity but also keeps the dust down because the machine is moving more rock and less air.

Likewise, operating the plant smoothly at a consistent rate improves production with no downtime when crushers ‘windmill’ and really kick up more dust.

There are all kinds of simple things you can do that don’t cost much and can have a big impact on dust levels. But it all has to come from the top down. There are many companies that peacefully co-exist with their neighbours. a

www.loadtech.co.za

www.global.weir

| May/June 2022 | Vol. 1 Issue 3 | www.quarryingafrica.com

www.kemach.co.za

www.ergindustrial.com

www.booyco-electronics.co.za