September2014

Vol 10 No 9www.crown.co.za

MODERN MINING

IN THIS ISSUE… 2,5 MVA gas-filled transformer launched Gem Diamonds opens its Ghaghoo mine Screening plant commissioned at Mupane Sentinel copper project nears completion

www.mdm-engineering.com

September 2014MODERN MINING1

COVERHansen + Genwest (previously Kopex Africa) has developed what it believes is a revolutionary gas-filled flameproof mining transformer aimed at the underground coal mining industry. See page 20 for further details.

EditorArthur Tassell

Advertising ManagerBennie Ventere-mail: benniev@crown.co.za

Design & LayoutDarryl James

CirculationKaren Pearson

Subscriptions:Wendy CharlesR410 (incl. Vat) per annumPostage extra outside RSA

PublisherKaren Grant

Printed by:Shumani Printers

The views expressed in this publication are not necessarily those of the editor or the publisher.

Published monthly by:Crown Publications ccP O Box 140, Bedfordview, 2008Tel: (011) 622-4770Fax: (011) 615-6108e-mail: mining@crown.co.za

Average circulation(April–June 2014)

4 378

MODERNM I N I N G

CONTENTS

MINING NEWS4 Construction of Otjikoto in full swing

6 Strike leads to drop in Northam’s profit

8 WSP Africa recognised for Kwale contribution

9 Lift II will extend Palabora’s life to 2033

10 ABG reports on projects at Bulyanhulu/North Mara

12 Bokoni turns in good quarterly performance

14 Hatch Goba ‘localises’ its office in Madagascar

16 Intelligent 3D model of Venetia shaft created

4 16

24

ARTICLES

PRODUCT NEWS51 Custom-made stemming trucks launched locally

52 New Cat wheel loader designed for support tasks

53 JLG units help assemble Cat machines

54 Crushing and screening solutions from HPE Africa

56 Burma Plant Hire opts for Komatsu machines

58 MBE provides iron ore beneficiation solutions

59 Main vent fan contracts for Bathopele completed

60 IPT appointed as Grindex distributor

REGULARS

30

38

COVER20 Hansen + Genwest launches gas-filled

mining transformer

DIAMONDS24 Gem triumphs in the Kalahari

GOLD30 Galane Gold commissions screening plant

COPPER34 Sentinel copper project all but complete

38 Contract at Copperbelt mine extended

FEATURE – BULK MATERIALS HANDLING42 Bulk handling range for the mining sector

45 Need for new thinking around transfer points

47 Modular equipment keeps production on track

FEATURE – INSTRUMENTATION & CONTROL48 “Phenomenal” turnaround at B&W

48 Smart sensor from Booyco Electronics

49 Laser gas monitors available from RTS

www.cobraprojects.com

September 2014MODERN MINING3

COMMENT

Zurich-based RepRisk has just re-leased a Special Report on the 10 ‘Most Controversial Mining Proj-ects’ in the world. Interestingly, three South African mines feature

in the report. Lonmin’s Marikana platinum mine tops the list, Harmony Gold’s Doornkop mine comes in at No 5 and Forbes & Manhat-tan’s Aviemore anthracite mine is ranked No 9.

Referring to Marikana, RepRisk says the mine “rose to international prominence in August 2012 when violent clashes between striking miners and local police resulted in at least 44 deaths and 78 injuries. In total, over 3 000 work-ers, who were paid on average US$2 per day, participated in the strike, demanding better pay and working conditions. The clashes have been described as the ‘bloodiest conflict between police and protesters since apartheid ended in South Africa in 1994’ and led to wider worker unrest across South Africa’s mining industry.”

As regards Doornkop, its inclusion in the list seems to be entirely based on the incident earlier this year at the mine in which nine min-ers lost their lives. Says RepRisk: “About 130 miners at Doornkop mine were underground when a fire, triggered by seismic activity, broke out 1 733 metres below the surface. The vic-tims were apparently unable to reach a refuge chamber. … The accident has been described as the worst accident in the South African min-ing sector since May 2008, when nine workers died when the cable of a shaft elevator broke at another mine.”

Moving on to the Aviemore mine in KZN, RepRisk notes that negative perceptions of the operation have mainly arisen because of the shooting of two workers in October 2012 by security personnel working for the mine owner. “Workers at the mine had been on strike for two weeks demanding higher wages and, on the day of the shooting, the security guards had allegedly chased around 100 strikers into the nearby bushes,” the report states. “The day after the shootings, police used tear gas to dis-perse 200 protesters who had blocked a main road near the mines.”

I think it’s probably important to stress that the report is not based on any deep research but rather measures the amount of negative coverage that various mines have attracted in the media, on the web and so on. As RepRisk itself says, its report documents “negative incidents, criticism and controversies related to the 10 mining projects that received the

World’s most controversial mining projects identified

highest RepRisk Index (RRI). The RRI is RepRisk’s proprietary algorithm that captures criticism and quantifies a project’s exposure to controversial ESG (environmental, social and governance) issues.”

Apart from South Africa, the only other country to have more than one mine in the list is – somewhat surprisingly – Canada. The Canadian mines that make the cut are the Mount Polley copper/gold mine (at No 4 in the list) and the Obed Mountain coal mine (ranked in seventh place), both of which are included because of perceived negative impacts on the environment. Mount Polley, for example, suf-fered a tailings dam disaster in early August this year which reportedly led to 10 billion litres of contaminated water and 4,5 million cubic metres of metals-laden fine sand find-ing its way into lakes and water courses in the vicinity of the mine.

Of the other mines in the list, ranked at No 2 is Turkey’s Soma Komur Isletmeleri coal mine, the site of the country’s worst ever mining disas-ter in May this year, when an explosion killed 301 miners. Says RepRisk: “At the time of writ-ing this report, the police were investigating the company’s executives for negligence as they were apparently aware of the mine’s deplorable safety conditions prior to the accident.”

Ranking at No 3 is the Monywa copper project in Myanmar, which has apparently been opposed by local communities, while the sixth-placed mine is the Abkhorak coal mine in Afghanistan, which suffered a gas explo-sion in September last year. At No 8 is the Zogota iron ore project in Guinea, also known as the VBG Simandou project, which has been plagued by accusations of corruption, extor-tion and money-laundering, while at No 9 (and co-ranking with Aviemore) is China’s Gyama polymetallic mine. Gyama, says RepRisk, “has been blamed for a landslide of rock and mud on March 29, 2013 that buried at least 83 miners who were sleeping near the site in Tibet.”

RepRisk is not – I must confess – an organ-isation I’ve heard of before but its website describes it as the “leading provider of business intelligence on environmental, social and gov-ernance risks.” Founded in 1998 as a social and environmental consultancy under the name ECOFACT, it was renamed RepRisk in 2010. It claims to have over 44 000 companies and 10 000 projects on its database, as well as 7 000 NGOs and 5 000 governmental bodies.Arthur Tassell

“As shown in the cases outlined in this report, safety problems may not only be an inherent risk of the work itself, but can also stem from negligence on the part of management, who may be looking for ways to cut costs and increase productivity, and who potentially endanger workers as a result.”

RepRisk in its report entitled ‘Most Controversial Mining Projects’

4MODERN MININGSeptember 2014

MINING News

Reporting on the three and six months ended June 30, 2014, Canada’s B2Gold Corp says that construction of its new Otjikoto open-pit gold mine in Namibia remains on budget and schedule with production expected to start in the fourth quarter of 2014. The mine is situated 300 km north of Windhoek between the towns of Otjiwarongo and Otavi.

According to the company, the mill and mining offices have been completed by a local Otavi contractor and construction of all the other administration buildings is 100 % complete. Mill construction activities con-

tinue to progress, the majority of concrete has been poured in this area and all leach and carbon-in-pulp tanks have been erected.

Construction of the primary crusher is complete while the shells of both the SAG mill and ball mills have been assembled in the milling area. Erection of the pre-leach thickener and the tailings thickener are in progress. The tailings facility is materially complete encompassing 1,5 million m3 of earth movement and including the place-ment of an impermeable liner to protect the environment.

A construction camp about 2 km north-

east of the mine is operational and able to accommodate construction workers at the Otjikoto site, although a large percentage of the workforce comes from Otavi and Otjiwarongo and is bussed to the site on a daily basis. At present, the camp houses 300 construction workers.

Surface mine development has pro-gressed well, says B2Gold. Project-to-date production stands at 8,4 Mt mined (waste and ore) against a budget of 8,6 Mt. Ore mining commenced in June 2014 and activities are focused on building the ore stockpiles in preparation for planned commissioning.

Pre-production expenditures for the six months ended June 30, 2014 totalled US$103,7 million (on a cash basis), including mobile equipment purchases of US$7 mil-lion, power plant costs of US$3,1 million and prestripping costs of US$4,6 million. Total construction and development costs remain in line with the Otjikoto feasibility study released in February 2013, including pre-development costs of US$244 mil-lion and deferred stripping estimates of US$33 million.

The Otjikoto feasibility study also assumed that a further US$60 million in mobile mining fleet and power plant costs would be lease financed. Leasing arrange-ments finalised in the fourth quarter of 2013 will finance US$36 million of mobile mining fleet costs, based on current for-eign exchange rates. The balance of the fleet and power plant costs has been funded from B2Gold’s existing cash flows and credit facilities.

The current mine plan is based on

Construction of Otjikoto in full swing

Another view of the site. Production at the mine is expected to start in the fourth quarter of this year (photo: B2Gold Corp).

September 2014MODERN MINING5

MINING News

Kabwe project EIS gets formal approval

BME annual drill and blast conference Now in its 22nd year, BME’s popular Annual Drilling and Blasting Conference at the CSIR in Pretoria is fast approaching. Considered a must-attend event for all involved in blasting operations and blast technology, the BME conference will take place on 6 November.

The conference is aimed not only at BME customers but at all practitioners in the busi-ness of blasting. Presentations will range from a journey into the future with Guy Lundy to practical insights and advice from technical experts in the field.

Lundy, a qualified futurist and experi-enced scenario planner, is passionate about the future of Africa and will present ‘Africa Rising’ – a dramatic growth story about the continent’s business opportunities. He has worked with Clem Sunter, one of Africa’s most highly regarded scenario planners, and shared platforms with some of its most well-known business leaders.

On the technical side, delegates will benefit from the experience of BME experts including: Director of Blasting Technology Tony Rorke, who this year will talk about exciting developments in unmanned aer-ial vehicle (UAV) data in blast evaluation; Manager of Detonator Technology Tinus Brits, on lightning sensitivity; and Senior Blasting Technician Christo van Zyl, on com-mon mistakes made in drilling and charging processes.

Those aware of BME’s pioneering work in utilising used oil as an ingredient in its explosives will also be fascinated by the presentation ‘Old Oil – New Future’ by BME’s Used Oil Manager, Emilia Mascis. This innovation has been hailed as a significant contribution to reducing the environmental impact of used oil.

Another familiar and highly-rated speaker at the event will be US-based Robert McClure, President of international consulting firm RA McClure Inc, who will talk about shocktube sensitivity. McClure was the International Society of Explosives Engineers’ Presidential Award recipient in 2011.

Also from RA McClure Inc is Technical Service Manager Tamara Wiseman, who will present on the topic of flyrock and blast design.

Further information is available on the website http://bmeconference.com/live, where delegates can confirm their atten-dance online. Registrations are limited and will be taken on a first-come-first-served basis.

The Otjikoto site is currently a hive of activity as this very recent photo of the plant area shows (photo: B2Gold Corp).

probable mineral reserves of 29,4 Mt at a grade of 1,42 g/t containing 1,34 million ounces of gold at a stripping ratio of 5,59:1 to be mined over an initial 12-year period. The current average annual production for the first five years is estimated to be approximately 141 000 ounces of gold per year at an average cash operating cost of US$524 per ounce and for the life of mine approximately 112 000 ounces of gold per year at an average cash operating cost of US$689 per ounce.

However, based on the positive drill results from the Wolfshag zone to date, on January 21, 2014 B2Gold announced plans to expand the Otjikoto mine in 2015, increasing ore throughput from 2,5 Mt/a to 3 Mt/a. The increased throughput will be achieved through the installation of a pebble crusher, additional leach tanks and mining equipment at a total cost of approximately US$15 million. Once the expansion is completed at the end of 2015, the company expects that the annual gold production from the main Otjikoto pit would increase to approximately 170 000 ounces per year.

AIM-listed Berkeley Mineral Resources (BMR), which is primarily engaged in pro-cessing mining tailings in Zambia through its wholly owned subsidiary Enviro Processing Limited (EPL), has announced t h a t t h e Z a m b i a E n v i r o n m e n t a l Management Agency (ZEMA) has issued a written approval of the Environmental Impact Statement (EIS) submitted by EPL for lead-zinc recovery and copper process-ing at Kabwe.

ZEMA’s approval of the EIS is based on its review of the EIS, on EPL’s environmental base line studies and information provided by EPL, on written and verbal comments from interested and affected parties and on its own site verification findings. The approval is subject to normal conditions relating to monitoring of protection for such matters as water and air quality, noise

levels, dust suppression and employee health. It is also subject to EPL implement-ing the project within three years.

ZEMA first notified EPL of the require-ment for an EIS in September 2013. For lead and zinc, the phase one process-ing, detailed in the company’s Definitive Feasibility Study, is anticipated to be by gravity and magnetic separation. For copper production, EPL’s plans are for a cementation process to produce concen-trates from ores to be secured from Zambia and the DRC via EPL’s trading connections.

BMR says it now intends to carry out final metallurgical studies to determine the optimal process route for treating the lead and zinc tailings so that pilot production can commence as soon as possible. In the meantime, EPL will commence small scale processing of copper ore secured locally.

6MODERN MININGSeptember 2014

MINING News

In its recently released results for the 2014 financial year (to 30 June 2014), Northam Platinum has reported a 93,4 % drop in operating profit to R61,5 million.

The group’s financial performance was dominated by the effects of the 11-week strike at the Zondereinde operation: rev-enue losses reached the R750 million level before a settlement was reached on 29 January 2014. In spite of the lower production volumes from Zondereinde, sales volumes were supplemented by Booysendal’s contribution and also from a release of inventory. The higher volumes, combined with the effects of a higher rand metal basket price, drove sales revenues higher to R5,3 billion (F2014: R4,4 billion), thereby compensating marginally for the

Strike leads to 93,4 % drop in Northam’s operating profit

moribund US dollar PGM prices.A 38,4 % increase in cost of sales reflects

the higher operating costs, increases in refining and related costs, along with a substantially higher depreciation charge, associated with the inclusion, for the first time, of costs relating to the Booysendal mine.

Commenting on the results, incoming Chief Executive Paul Dunne paid tribute to his predecessor Glyn Lewis’s contribution to the company and its fortunes. “With Glyn’s determination, Booysendal has been successfully constructed and commis-sioned. The company’s second PGM mine on the Eastern Limb, now in full ramp-up stage, has transformed Northam, adding to its production profile, reducing the

company’s operational risk and enhancing its optionality.” He added, “The company I joined is in good shape – both in terms of its assets and its people.”

The strike seriously affected produc-tion at Zondereinde. After the strike it took some three months before normalised pro-duction levels were resumed. By the end of the financial year production had improved considerably. The effect of the strike on pro-duction was marked by a drop of 18,9 %. However, PGM sales were down by a lesser extent, or 8,2 %, at 9 827 kg. Unit costs were abnormally high, skewed by the lower pro-duction volumes. Capex for the year came in at R351 million, allocated mainly to the smelter rebuild, the deepening project and the hostel conversion programme.

The smelter was rebuilt and success-fully recommissioned thereafter at a cost of R54,0 million. The facility is operating normally.

Progress on ore reserve development in the north-west quadrant of the mine and the deepening project was cur-tailed during the strike. Following a slow restart, these activities are progressing satisfactorily.

In the absence of further disruptions, Zondereinde mine’s production in the year ahead should be at normalised levels, while costs will continue to reflect the inflation-ary effects of higher wages and electricity tariffs and the weaker rand. Capex in the coming year is forecast at R331 million. The deepening project should absorb approxi-mately R105 million, with the balance allocated to routine capex items, including R28 million for an autoclave replacement and a further R42 million for the hostel conversion programme.

Booysendal, the group’s new mecha-nised mine, continues to ramp up to steady state, anticipated by the end of 2015. The mine posted an operating loss for the year, but is anticipated to make a positive con-tribution in F2015.

At R539,6 million, capital expenditure was significantly lower than the previous year, given the near-completion of the con-struction and development work. Forecast capital expenditure in F2015 is expected to be R483,4 million. This includes R50 mil-lion to be spent on a project to investigate the feasibility of mining Merensky ore at Booysendal.

Booysendal, Northam’s new mine on the Eastern Limb of the Bushveld Complex, is a mechanised opera-tion. It is currently in a ramp-up phase, with steady state production anticipated by the end of 2015 (photo: Northam Platinum).

MDM wins Kinsevere copper mine contractMDM Engineering Group, the AIM-listed minerals process and project management company focused on the mining industry, has been awarded a contract with MMG Limited’s Kinsevere copper mine, located in the DRC’s Katanga Province.

MDM will provide specific design and detailed engineering support on a number of MMG-identified projects. The projects include process optimisation and asset utilisation improvements being carried out

as part of MMG’s broader operational excel-lence programme at Kinsevere.

Comments Chris Bushby, MDM Project Manager: “MDM’s extensive copper and cobalt experience has enabled us to offer a high quality, cost effective solution to MMG’s Kinsevere copper project. We also have an unrivalled understanding of the industry in the DRC following the execution of two copper projects and a gold project, all within the last 20 months.”

September 2014MODERN MINING7

MINING News

The Procurement Leaders Global Awards are reported to be the most celebrated and sought after awards in procurement, representing the best initiatives, individuals and companies across the world.

Weir Minerals believes it can therefore be justi-fiably proud of its receipt of the 2014 Procurement Leaders Global Award for External Collaboration, in conjunction with Anglo American. The award, which closely follows the signing of a Global Framework Agreement between the two com-panies, underlines the giant strides that Weir Minerals Africa has made in developing and fos-tering an excellent supplier-customer relationship with Anglo American.

Hanno Viljoen, Key Account Manager – Anglo American for Weir Minerals Africa, says the basis of the company’s nomination was the efficiency and cost savings provided to Anglo American through new technology within a short space of time. The nomination highlighted the mutually beneficial relationship that both companies have developed.

Craig Walters, the Global Category Manager at Anglo American who manages the Weir Minerals account, emphasises that for customer interac-tion to be fruitful, suppliers need to think outside the box and be able to change customer mind sets. This is especially pertinent in relation to the efficiency of products and the role they will play in creating profitability and sustainability for customers. Further focus is placed on lifecycle advantages and the ability to provide tangible savings on investment, maintenance and down-time, with a concurrent increase in productivity.

Weir Minerals Africa wins prestigious award

David Rae, Chair of Judges and Content & Community Director at Procurement Leaders; Craig Walters, the Global Category Manager at Anglo American who manages the Weir Minerals account; Rob Fawcett, Sales, Marketing and Engineering Director at Weir Minerals; and Boris Becker, former professional tennis player (who was the host at this year’s awards ceremony held at the London Hilton).

Viljoen plays a critical role in ensuring that the interface between Weir Minerals and Anglo American is one that nurtures open lines of com-munication. “As a key account manager I am responsible for interpreting the needs of the cus-tomer and sharing these with the relevant teams at Weir Minerals Africa,” he explains. “This facilita-tive role becomes more entrenched and intricate as time progresses and the ability to anticipate and proactively meet expectations becomes eas-ier to achieve.”

Universal granted Mining Right for BrakfonteinUniversal Coal, listed on the ASX, has been granted a Mining Right over the Brakfontein coal project (50,29 %-owned) by the Department of Mineral Resources.

Located within approximately 20 km of the company’s Kangala colliery in South Africa’s Witbank coalfield, Brakfontein has the potential to be Universal Coal’s third mine. With the Mining Right in hand and having already secured the National Environmental Management Act (NEMA) authorisation, the project now only awaits the granting of the Integrated Water Use Licence and the Waste Licence (IWUL) before development activities can commence.

Brakfontein currently hosts a JORC-compliant thermal coal resource of 87,6 Mt, of which 70,5 Mt are in the measured category. The company is pro-

gressing well with a feasibility study, scheduled for finalisation by the end of the year.

Commenting on the granting of the Mining Right, Universal Coal’s CEO, Tony Weber, said: “We are delighted to have taken another key step in the development of Brakfontein, which will be our third mine following successful development of the Kangala colliery and the New Clydesdale colliery acquisition.

“Kangala has excess capacity, enabling pro-duction to increase from its current 2,4  Mt/a Run-of-Mine (ROM) rate to 4,25 Mt/a. Given Brak-fontein’s close proximity to the Kangala colliery, Universal Coal is evaluating the trucking of ROM coal to Kangala as an option in the feasibility study, thereby substantially reducing capital development costs and the scale of the water licence required.”

8MODERN MININGSeptember 2014

MINING News

WSP Africa, one of the largest engineering consultancies in Africa, has been recog-nised for its role in the Kwale mineral sands mining project in Kenya at the annual Consulting Engineers South Africa (CESA) Aon Engineering Excellence Awards. The Kwale project is reportedly the largest min-ing investment in Kenya since 1911.

Australian company Base Resources Limited appointed WSP in 2011 to manage the development of the Export Facility, pro-viding EPCM services for the building of a new dedicated port facility for the mine at the Port of Mombasa. The mine is located some 10 km from the coast and approxi-mately 50 km from Mombasa and is focused on mining ilmenite, rutile, and zircon.

“We provided project management,

and loading of mineral sands into the berthed bulk carriers.

“Strict deadlines had to be adhered to with a significant amount of engineering that had to be completed in a very short space of time. For example, the design report and tender drawings had to be submitted to the client for review only two months from starting the design phase. This required assumptions on some design parameters, particularly geotech-nical parameters, which subsequently had to be confirmed,” says Andre van Tonder, Divisional Director for WSP’s coastal engi-neering team in Stellenbosch.

In addition, van Tonder says, the site was quite restricted, being only approxi-mately 13 300 m2 in size. The marine facility and its operations had to be positioned between the existing ferry terminal, an emergency slipway and the shipping chan-nel boundary.

The client also required WSP to ensure that local contractors would qualify for tendering. Consequently, designs were adapted to suite local capabilities. The designs of the administration building, maintenance workshop and guard house were also based on the use of local mate-rial. As such, the structures were built using locally available bricks made from coral rock.

The 7 000 m2 storage shed has a roof structure supported on a combination of concrete and steel columns. Care was taken to utilise natural light and ventila-tion. The apex of the roof structure was designed with ventilation slots to dispose of dust and plant fumes.

WSP Africa recognised for Kwale contribution

WSP Africa provided EPCM services for the building of the new dedicated port facility serving the Kwale mineral sands mining project in Kenya (photo: WSP).

civil, structural, marine and electrical engineering services for the project – a substantial undertaking, but one where we were able to really showcase our multi-disciplinary expertise. To be considered for this prestigious award is testimony to the hard work and commitment from the entire team,” says Mathieu du Plooy, CEO of WSP in Africa.

The facility comprises a large storage shed for the mineral sands, an access tres-tle and load-out platform with breasting and mooring dolphins, as well as convey-ors to transport material to a dedicated ship-loader. WSP provided a specialist con-sulting engineering team to ensure local representation complemented by special-ist skills in the fields of storage, transport,

Kalagadi launches enterprise development initiativeMining Company Kalagadi Manganese, in partnership with the Department of Mineral Resources, has launched an enterprise development programme in Kuruman, Northern Cape.

The initiative will see eight women and two men running their own compa-nies which will be contracted to one of Kalagadi’s mining operations.

This group of business men and women has reportedly been equipped with finan-cial, business and managerial skills to ensure that the programme and their businesses are sustainable. The group will be registered

as a co-operative and will be contracted to the mine to clean and collect spill-overs of manganese from the belt which will be repatriated back for processing.

Provided by the South African Precious Diamond Regulators, the training – which started in June 2014 – also includes skills on how to identify different grades of manganese to ensure that the identified candidates are equipped with the nec-essary skills and understanding of the environment they are working in.

The Chairperson of Kalagadi Manga-nese, Daphne Mashile-Nkosi, said she was

delighted with the launch of the project as it would go a long way towards empower-ing the local community and promoting sustained development.

“As we grow our operations, we also need to empower local communities by fostering a culture of entrepreneurship,” she said. “Studies indicate that small and medium sized enterprises are the engines of economic growth and we believe that this intervention by Kalagadi Manganese and the Department of Mineral Resources will further revitalise the local economy and empower these men and women by giving them a solid foundation to become future industrialists.”

September 2014MODERN MINING9

MINING News

Block-cave development will extend Palabora’s life to 2033A decision on a block-cave mine development project worth over R9,3 billion by Palabora Copper (Pty) Ltd is expected imminently (and could well have been announced by the time this issue is in print). The project, called Lift II, is expected to increase the life of mine by another twenty years, until 2033, and some R2 billion has already been spent on early works – what is now a bankable feasibility study. The mine is expected to continue to produce copper and magnetite.

“A bankable feasibility study was completed in May 2014 and provided a sound technical and positive business case to proceed to full execution with the Lift II project,” says the company’s General Manager for Growth Division, Nick Fouche. “The study presented an option, at a 90 % confi-dence level, to develop a new Lift II mining footprint 450 m below Lift I that will ensure a continuation of copper mining in Palabora until 2033.”

He reports that about R2 billion has already been spent to date on the development of a twin decline and supporting engineering infrastructure – known as early works. This strategy has put a significant positive out-look on the project, ensuring that the critical access to the undercut and the Lift II production level is ready for construction, at the scheduled time.

In May 2014, Palabora Copper’s board recommended to the sharehold-ers that the project go to full execution. “However, the new shareholders, having acquired the business in August 2013, wanted more information to make an informed decision and to also decide on the funding model that should be used,” says Fouche. He adds that while the board did not provide a full approval for the entire project, certain works were allowed to continue pending the final shareholders’ decision.

Palabora Mining Company, previously owned by Rio Tinto and Anglo American, was acquired by a group of companies including a Chinese consortium, which includes one of China’s steel giants, Hebei Iron & Steel Group Co, Tewoo, General Nice and China Africa Development Fund, as well as the Industrial Development Corporation of South Africa SOC Limited (IDC).

Underground at Palabora – the proposed Lift II project will extend the life of the mine by approximately 20 years (photo: Palabora Copper).

10MODERN MININGSeptember 2014

MINING News

According to its half year report for the six months ended 30 June, African Barrick Gold (ABG) is making good progress with its various projects at its Bulyanhulu and North Mara mines in Tanzania.

In April 2014 the Board approved the next step in the optimisation of Bulyanhulu through the acceleration of mining from the Upper East Zone (Bulyanhulu Upper East). The Zone is expected to produce 1,7 Moz of gold, averaging 60 000 ounces per annum over a life in excess of 25 years, at an AISC of below the target run rate for Bulyanhulu for year-end 2015 of US$900 per ounce.

Following the Board approval, the mine undertook waste development in the Zone at a capital cost of US$4,7 mil-lion in Q2 2014. As expected, the mine will commence ore development in Q3 2014

ABG reports on projects at Bulyanhulu and North Maraand this is expected to lead to production from the Upper East Zone of approxi-mately 15 000 ounces of gold in H2 2014, weighted towards the fourth quarter. ABG continues to expect that the 2014 capital requirements for the project will be approximately US$15 million.

ABG says it has also progressed the accelerated development of the Bulyanhulu Deep West Zone through a contractor to increase access to higher grade ore from Q4 2014. During Q2 2014, ABG incurred underground development capital costs of US$4,8 million for the proj-ect and expects to incur similar costs per quarter for the remainder of 2014.

ABG also reports that during the second quarter it progressed the commissioning of the new CIL circuit at Bulyanhulu, which will add over 40 000 ounces per annum

once fully operational, and is nearing completion of the commissioning stage. Towards the end of June, roughly 6 500 tonnes of rougher tailings were treated and pumped into the new CIL circuit, resulting in 273 ounces of gold being pro-duced in circuit.

“We expect commissioning to be com-plete in early Q3 2014 with the first gold pour in August and the ramp up of pro-duction to continue throughout the third quarter,” says ABG. “We continue to expect production of 20 000 ounces in 2014 from the project, and are investigating an option for accelerating the retreatment of the historic higher grade tailings in prefer-ence to the rougher tailings.”

Turning to the North Mara mine, ABG reports that the feasibility study into the potential to mine Gokona Cut 3 via an underground operation progressed well in the second quarter and is on track to be presented to the board for approval in Q4 2014. During Q2 2014, ABG made the final decision on the location of the exploration portal which will provide the opportunity to develop a better understanding of the orebody, provide initial access to ore and drilling access to the deeper extensions of the orebody. Early works towards the con-struction of the portal are in progress. The total expansionary capital cost of the portal is expected to be around US$10 million.

African Barrick’s North Mara mine. The company reports that the feasibility study into the potential to mine Gokona Cut 3 via an underground operation progressed well in the second quarter (photo: ABG).

Montero Mining enters funding agreementMontero Mining and Exploration, listed on the TSX-V, has entered into an agreement with Ovation Capital to fund development of Montero’s phosphate properties in South Africa. Ovation Capital is a South African-based investment firm that is currently developing a portfolio of mineral beneficia-tion projects focusing on a targeted set of industrial minerals.

Ovation will earn a 30 % interest in

Montero’s phosphate properties by complet-ing a Pre-Feasibility Study and a Feasibility Study for an integrated phosphate rock and phosphoric acid operation at Saldanha Bay. Ovation has mandate agreements with Outotec and Sebata Group to complete these studies within a two-year period. A definitive agreement is currently being final-ised and is subject to legal and technical due diligence, as well as regulatory approvals.

September 2014MODERN MINING11

MINING News

Australia’s IMX Resources has announced that it has confirmed and expanded the graphite potential of its Nachingwea property in south-east Tanzania after com-pleting initial geophysical analysis on the extensive VTEM survey data sets covering the majority of its 6 800 km2 tenement holding, with graphite targets apparent over the entire licence area.

At Nachingwea, IMX is carrying out exploration at its Chilalo graphite prospect and at its Kishugu gold prospect and there is a significant nickel resource at its Ntaka Hill nickel project.

The VTEM analysis has confirmed that the Chilalo prospect is the highest prior-ity graphite target within the broader Nachingwea property, with the prospect composed of multiple layers of interpreted graphite horizons ranging in thickness from 50 m to +200 m. The horizons at the Chilalo prospect alone account for over 54 lineal kilometres of strike.

Drilling at Chilalo is expected to com-

IMX explores graphite potential at Nachingweamence in October 2014 to test the best targets, confirm the extent of the mineralisation, grades, flake size fractions and provide samples for metallurgical test work.

In addition, the analysis has identified the Chilalo North pros-pect, located to the north-east of Chilalo, which presents as a very high intensity VTEM anomaly, measuring approximately 300 m x 500 m, with the potential to host a significant volume of high-grade graphite mineralisation.

Three rock chip samples col-lected from the Chilalo North prospect have been assayed, returning grades of 17,5 %, 17,6 % and 19,5 % carbon.

IMX Managing Director Gary Sutherland said the results of the geophysical analysis were highly encouraging. “Based on the success of this initial analysis, and in light of Nachingwea’s proximity to other high-

IMX has previously intersected graphite at the Ntaka Hill project, 20 km south-west of Chilalo, whilst targeting nickel sulphide mineralisation. This photo of the diamond core from Ntaka Hill shows the coarse flake nature of the graphite mineralisation, with a similar style of mineralisa-tion expected at Chilalo (photo: IMX Resources).

grade graphite resources, we are very enthusiastic about the graphite potential of the Chilalo and Chilalo North prospects and the Nachingwea property more broadly. We look forward to getting an initial drill-ing programme underway,” he said.

Giyani Gold Corp, listed on the TSX-V, reports it has entered into a binding letter of intent agreement with the shareholders of Horizon Enerji A.S. (Horizon) and Sumo Coal which outlines the general terms and conditions of a proposed transaction. The transaction will lead to Giyani acquiring all the issued and outstanding securities of Horizon and Sumo.

Upon completion of the transac-tion, Giyani will hold a 100 % interest in Horizon’s Ceyhan project, a fully permit-

Giyani Gold plans Sumo acquisitionted crude oil storage and dry bulk cargo port development project in Turkey, and a 100 % interest in Sumo, a cash-flow gener-ating coal operator in South Africa.

“Giyani has assembled a unique pack-age of energy assets that will mould our company into a major player in the oil ser-vices and energy sector. We have delivered on our strategy of acquiring a cash-flow generating asset, which will elevate the profile of our company and remove explo-ration risk moving forward,” comments

Duane Parnham, Executive Chairman of Giyani. “The energy sector is strong and we anticipate that as the sector continues to strengthen our shareholders will be rewarded based on the superior projects Giyani is acquiring and the team we have assembled to progress them.”

Sumo operates in the Witbank coal-field in Mpumalanga and holds numerous thermal coal assets. As part of its growth strategy, it has formed independently operating subsidiaries in the areas of exploration, drilling, mining, coal benefi-ciation and marketing.

12MODERN MININGSeptember 2014

MINING News

Three-year cycle adopted for trade showAfter premiering in September last year, the next BAUMA CONEXPO AFRICA show takes place at the Johannesburg Expo Centre (JEC) from September 15 to 18, 2015. Following next year’s exhibition, BAUMA CONEXPO AFRICA will move to a three-year cycle, meaning the next fair will then be held in 2018. This decision was made after close consultation with local and international industry representatives who recommended the three-year cycle for the markets of Africa.

“We made this strategic decision based on the many discussions we have held since the extremely successful premiere,” says Elaine Crewe, CEO of organisers BC Expo South Africa. “The three-year cycle clearly positions BAUMA CONEXPO AFRICA as the leading

trade fair in Africa for the global construction and mining industry.”

Lawrence Peters, Chairman of CONMESA (Construction and Mining Equipment Suppliers’ Association), is also pleased by the news: “As a local partner, we are pleased that the discussions were so productive and that the organisers of BAUMA CONEXPO AFRICA decided to change the frequency of future events. The three-year interval suits the region because it depicts the market more accurately. It also gives local and interna-tional companies additional time to ensure that they are sufficiently prepared for the intense business activity at this event.”

Additional information is available from website www.bcafrica.com.

Atlatsa Resources, which controls and operates the Bokoni platinum mine on the Eastern Limb of the Bushveld Complex in Limpopo Province, reports that its rev-enue for the quarter ended June 30, 2014 increased 21 % to US$58,6 million and that its PGM production was up 9 %.

“Despite a lacklustre Rand PGM basket price, our second quarter performance was pleasing, supported by another quar-terly increase in tonnes milled and PGM ounces produced,” comments Harold

Bokoni turns in a good quarterly performanceMotaung, CEO of Atlatsa. “We continue to ramp-up the development of our two new shaft complexes, Brakfontein and Middelpunt Hill, which bodes well for our targeted growth of 10 % in production of PGM ounces for FY2014, as well as an improvement in unit costs and cash flow generation in the medium term.”

During the second quarter of 2014, Bokoni produced 46 777 PGM ounces compared to 42 901 PGM ounces during the second quarter of 2013. The increase is

Opencast operations at the Bokoni platinum mine (photo: Atlatsa).

attributable to an improved underground mining performance, together with the Klipfontein Merensky opencast operation increasing its production to 2 978 PGM ounces during Q2 2014, compared to 703 PGM ounces in Q2 2013.

Primary development increased by 13 % quarter-on-quarter to 2 797 m as a result of good progress being made at the Brakfontein and Middelpunt Hill ramp-up projects, both on the decline shafts and lateral development.

This development rate is expected to be maintained over the next year as the operations focus on increasing face length to improve mining flexibility, whilst at the same time moving towards steady state targets of 100 000 tonnes per month (tpm) and 60 000 tpm at the Brakfontein and Middelpunt Hill underground operations, respectively.

The Merensky opencast mine has now reached steady state, with an abil-ity to maintain a production rate of up to 40 000 tpm for the next three years, as Bokoni’s underground mining operations ramp up to 160 000 tpm from the current 130 000 tpm base.

Delivered grades were lower as a result of an increase in lower grade opencast material and increased secondary devel-opment at underground operations.

September 2014MODERN MINING13

MINING News

Tonkolili gets “injection of capital”African Minerals Limited (AML), the devel-oper and operator of the Tonkolili iron ore mine in Sierra Leone, has announced an injection of liquidity at the project level, and a change of management. Both are the result of an agreement concluded with Shandong Iron and Steel Group, AML’s Tonkolili project partner.

Comments Roger Liddell, Senior Indepen dent Director of AML: “The first half of 2014 has been an extremely busy period for African Minerals. Exports remain on track to meet our annual sales guidance of 16-18 Mt with cash costs of US$34-36/t which remains unchanged; the wet season has started aggressively, but we are pleased to report that production and export sales have been unaffected, with 9 Mt already exported in the first half of the year.

“We have established our DSO strategy, which will see us commission de-sliming circuits to produce year round shippable products and to cease producing and sell-ing lower margin A32; most excitingly,

we reported that our expansion into high value concentrate could be completed at a significantly lower capital cost and in an accelerated timeframe than previ-ous expectations to provide substantially increased margins; and we also extended our DSO resource to provide flexibility to further defer any additional concentrator requirements.

“Despite the good progress at the oper-ations, the last few weeks have thrown up a perfect storm of low iron ore prices and heightened concern over the serious Ebola virus disease outbreak that is afflicting several countries in West Africa, amongst others,” Liddell continues. “After generating a strong operating margin in Q1 2014, the second quarter has seen our received FOB price fall, putting pressure on our working capital requirements, as noted in our mar-ket update on 6 August 2014. However, we are confident that the establishment of our de-sliming circuits later this quarter will provide an immediate uplift to our rev-

enue and a marked reduction in cash cost, returning the project to a cashflow positive status.

“We are very pleased to announce that, during a project shareholders meeting held between 9 and 11 August 2014 in Jinan, both shareholders have agreed to access the funds in the Hong Kong joint project account, currently totalling US$284 million, not only for construction capital, but also for general working capital purposes, with immediate effect. A condition of the release of these funds into the project companies is that there is a financial and operational separation of their activities from AML. In addition, Shandong has requested certain changes to the management structure of the project companies, which has been agreed by the Board of AML.”

Alan Watling, previously CEO of the company during the construction phase of the Tonkolili project and associated infrastructure, who retired during 2012, will once more take on the role of CEO of the project companies and of AML. He suc-ceeds Bernard Pryor.

14MODERN MININGSeptember 2014

MINING News

Consulting engineering and project imple-mentation firm Hatch Goba has displayed its commitment to the localisation of skills development and long-term job creation in Madagascar, after transforming its regional office in the country from one with an entirely expat-based workforce to one that is 95 per cent local – all within the space of just four years.

Hatch Goba Site and Capex Manager Yanick Laliberté notes that the office was originally established in 2010 in Fort Dauphin to provide project management services directly to QMM – an ilmenite and zircon mining operation jointly owned by Rio TintoQIT Madagascar Minerals and the Malagasy state.

“The branch was originally comprised entirely of expats from South Africa and Canada. As it began to establish a more permanent position in the country, empha-sis was placed on localising the staff base. The Fort Dauphin team currently consists of 15 professionals in various disciplines,” he states.

“The combined expertise of the team ensures that they are able to effectively manage capital expenditure (capex) projects from pre-feasibility study up to implementation. We aim to become a world class project team and, to achieve

Diesel Power makes a difference at ThakaduAfrican Copper, quoted on AIM, has pro-vided a production and exploration update for the first quarter of its financial year to 30 June 2014. The company’s flagship project is the copper producing open-pit Mowana mine. African Copper also owns the rights to the nearby Thakadu-Makala deposit. Both deposits are situated on the Matsitama belt, located close to Botswana’s second largest city, Francistown, in the north-eastern part of the country.

During the quarter, the company produced 2 703 tonnes of copper in concen-trate, which was 12,1 % down on the figure for the comparable period last year.

Ore processed – while increasing to 169  565 t from the previous quarter’s 163 391 t – continued to be affected by a lack of good quality ore from the Thakadu pit due to the backlog of waste stripping required; however, the new mining con-tractor Diesel Power, who commenced operations in April 2014, is beginning to

reduce this backlog. Improved ore produc-tion from the Thakadu pit is expected in the coming quarter.

The Mowana process plant had above target availability but variable utilisation due to erratic ore supply from Thakadu dur-ing the quarter.

Infill drilling in the Thakadu pit was car-ried out to allow updating of the Thakadu geological model. Infill drilling also started in the Mowana pit to enable re-categorisa-tion of inferred resources to measured and indicated resources for incorporation into the Mowana Life of Mine plan.

Comments Jordan Soko, Acting Chief Executive of African Copper: “We are pleased with the mining progress that Diesel Power is making at the Thakadu pit. With improved ore production from Thakadu and more stable operating conditions at the Mowana plant, we are well positioned to increase production levels for the remainder of our financial year.”

Hatch Goba ‘localises’ its office in Madagascar

this objective, we need to improve our competency and skills, sustain and rein-force our client relations and meet the current capex budget.”

Despite the overwhelming success of the Fort Dauphin office transformation programme to date, Hatch Goba Industrial Minerals Director and Project Manager Giulio Capuzzimati admits that a number of challenges have been encountered. “When the need for a local office in Madagascar was recognised, there was concern that local staff could be isolated from the rest of the organisation,” he says.

The Hatch Goba team in Madagascar (photo: Hatch Goba).

As a result, Capuzzimati highlights the fact that training and development of the Malagasy staff has been a priority for Hatch Goba. “Shortly after starting at the com-pany, all of the employees were brought to the Johannesburg office for internal train-ing, which was developed to ensure that they were successfully integrated into the global company.”

In addition, Hatch Goba offers Malagasy staff external training. For individuals focusing on a specific field, such as project management or engineering, Hatch Goba has put in place a training programme that enables them to study through institutes and training organisations in South Africa.

To ensure that the Malagasy staff have access to all the experience and knowl-edge that they may require, Hatch Goba is also currently in the process of estab-lishing a global mentorship programme. This programme will give employees the opportunity to spend an extended period of time at the Hatch Goba offices in Johannesburg or the Hatch offices in Montreal, Canada.

Another challenge has been the lan-guage barrier, as French and Malagasy are the dominant languages in Madagascar. To improve communication between the Malagasy staff and the English-speaking South African mentors, English lessons are being offered to the local team.

Laliberté notes that the transformation programme has proven to be highly effec-tive, as Hatch Goba was recently awarded another three-year contract by QMM for all onsite and offsite EPCM services for capex projects.

September 2014MODERN MINING15

MINING News

As South Africa cries out for a larger pool of engineering skills, the sector needs to ensure that there are no barriers to the entry of women into professional careers that contribute to the engineering envi-ronment. This is the view of SRK Consulting (SA) Managing Director Peter Labrum.

While the number of women in con-sulting engineering has certainly grown, Labrum said this growth has been mainly in the sciences – such as environmental science, geology, hydrology and related disciplines – rather than in civil, mining or electrical engineering, for instance.

“In the consulting field, there have always been many more women in the sciences than in engineering per se but there is also a definite increase in the number of women studying engineer-ing,” said Labrum. “And of course many of the scientists will work in an engineering environment.”

He emphasised the need for the pro-fession to attract young people who were passionate about the field, irrespective of gender, who really wanted to work as engineers.

“Just as there should be no barriers or discrimination against anyone, I would also caution against applying any artificial incentives for people to enter this line of work,” he said. “The danger is that by ‘push-ing’ individuals into certain careers, you could get the wrong sort of person.

“In a profession like engineering, you really need the right people. If you want the best engineers, you must have people who genuinely want to be engineers, who are passionate about it.”

He said this was how SRK earned its reputation. “Our business is really based on meritocracy – we want to just have the

best people. That’s how we’ve been so suc-cessful. Whether the best person is male or female is irrelevant. Their progression through the company is based on their value to the business,” he said.

SRK’s complement of female employees in professional posts in its South African offices now exceeds 90 experts, including mining engineers, civil engineers, chemi-cal engineers, rock engineers, engineering geologists, hydrogeologists and environ-mental scientists. Women also play key roles in the firm’s fast-growing discipline of stakeholder consultation and public participation – an element of mining and other industrial projects that is becoming recognised as a foundation to sustainable development.

“Many of the roles at the level of princi-pal – which usually requires 12 to 15 years of experience – are occupied by women in SRK today, from which they can move into the managerial levels of associate and then partner,” said Labrum.

Women in SRK’s executive management team include hydrogeologist Diana Duthe and environmental scientist Briony Liber – both principal consultants and partners

Consultancy now has more than 90 female professionals

SRK Consulting’s complement of female employ-ees in professional posts in its South African offices now exceeds 90 experts (photo: SRK).

in the firm. Vassie Maharaj, who specialises in stakeholder engagement, and Manda Hinsch a water specialist, are both associ-ate partners, as are environmental scientist Dr Laetitia Coetser and Sandy McDonald, who is responsible for the GIS section in the company.

Triton Minerals appoints Technical DirectorASX-listed Triton Minerals has announced that Non-Executive Director Alfred Gillman has been appointed to the executive role of Technical Director, effective immediately.

“Mr Gillman’s appointment as Technical Director is a key step in securing the techni-cal expertise and management experience needed to help guide and rapidly progress the Mozambique graphite project through the next critical stages and advancement towards production,” says Brad Boyle, Triton’s CEO.

Gillman, a past Group Exploration Manager at Harmony Gold, has over 30 years of experience as a geologist in gold, base metals, uranium and industrial minerals. He has extensive experience in exploration and project development in various parts of the world including Australia, Papua New Guinea, Africa, the US, Russia and Central Asia.

Triton holds an 80 % interest in three graphite projects – Ancuabe, Balama North and Balama South – in Mozambique.

16MODERN MININGSeptember 2014

MINING News

Shaft Sinkers awarded additional work at LeeuwkopShaft Sinkers Holdings, listed on the LSE, recently announced that it has been awarded additional work by Afplats on its Leeuwkop project, located near Brits. Afplats is controlled by Impala Platinum.

The scope of work under the new con-tract includes the continuation of sinking activities on the main shaft from a depth of 984 m to 1 307 m, as well as the con-struction of two station breakaways for the establishment of horizontal tunnels to access the orebody at 1 207 m and 1 237 m respectively. The additional work is sched-

uled to be completed in the second half of 2015 and has a total value of £7 million. The contract is priced on a rates basis.

Afplats has awarded the Leeuwkop sink-ing contract in a number of phases, with Shaft Sinkers starting work on the project in June 2011. The company completed pre-sink and mobilisation work in April 2012 with main sinking activities commencing concur-rently. Shaft Sinkers was awarded further additional contracts at Leeuwkop in August 2013 and December 2013. The intended final depth of the main shaft is 1 561 m.

In executing the detailed engineer-ing design for the permanent surface and underground infrastructure at De Beers’ R20-billion Venetia diamond mine underground project, WorleyParsons has harnessed a methodology to create an intelligent 3D model of the vertical shaft that incorporates the historic and techni-cal information of every component.

It is believed that this is the first time this methodology is being used on a ver-tical shaft project from the design stage and this capability is expected to become a significant market differentiator for the global WorleyParsons organisation, one of the world’s largest EPCM businesses.

“In using 3D modelling to design the vertical shaft from scratch, the client has

been able to review our designs and have any changes incorporated and represented in the model well before fabrication even commences. This has effectively shortened and de-risked the design process,” says Ryan Illingworth, WorleyParsons’ Project Manager on the Venetia project.

“Design traditionally begins with 2D modelling and the 3D environment is only then modelled when fabrication of the components begins. However, since the many separate 2D drawings are not linked to each other, there’s always a risk when it’s assembled/constructed that there will be incompatibilities. On the Venetia pro-ject, as the design process has advanced, we’ve progressively created a 3D model that presents our customer with a visual

WorleyParsons has created an intelligent 3D model of the vertical shaft at Venetia that incorporates the historic and technical information of every component.

Intelligent 3D model of Venetia shaft createdrepresentation of the infrastructure.

“Once the mine moves into production, management will be equipped with an intelligent 3D model of the shaft that can be used for maintenance planning and control. Because the model has a database at its core, it will also be able to integrate with other De Beers database systems.”

The WorleyParsons draughting team deployed on the project spent the greater part of a year prior to commencement of the design phase developing a method to network several Autodesk software pack-ages in a complex array to allow for the creation of the intelligent 3D model.

WorleyParsons is a major international provider of project delivery, engineering and consulting services to the resources and energy sectors and complex process industries. It is a recognised market leader in headgear design, having successfully delivered a new generation of headgear concepts at Impala Platinum’s No 17 and 20 shafts and Konkola Copper Mines’ No 4 shaft.

WorleyParsons has executed the feasi-bility study on the permanent infrastructure for the Venetia project and has embarked on the detailed engineering work. As an Anglo American Tier 1 supplier, WorleyParsons is providing engineering consulting ser-vices that include detailed engineering, execution and support in procurement and construction management.

September 2014MODERN MINING17

MINING News

Tawana makes appointments for Mofe Creek PFSASX-listed iron ore developer Tawana Resources has appointed two firms to man-age and coordinate the major design and logistics components of a Pre-Feasibility Study (PFS) for its Mofe Creek project in Liberia, West Africa.

Globally recognised mining and miner-als design and development groups Tenova Mining and Minerals and Engenium will manage the PFS for Mofe Creek.

Tenova has a strong track record in deliv-ering projects similar to Mofe Creek and

recently completed a Scoping Study for the project. Engenium is a leading project and study management delivery company servic-ing the mining and resource sectors with a specific focus on mine, port and rail projects.

The PFS, led by Tawana’s Project Director, Noel O’Brien, will build on the results of Mofe Creek’s Scoping Study which indicated a very positive economic potential. The Scoping Study considered an early start-up, low capital cost project with a production rate of up to 2,5 Mt/a.

Lace to enter production ahead of scheduleaverage recovered grade of 5,78 carats per hundred tonnes (cpht), against a budget of 5,00 cpht. After the period end, a 15,2 carat white octahedral diamond was recovered, the largest gem found since tailings repro-cessing began in 2008.

C o m m e n t i n g o n t h e r e s u l t s , DiamondCorp CEO Paul Loudon said: “The period under review saw us move

closer to our goal of commencing long-life underground kimberlite mining at the Lace mine. Our constant attention to min-ing and development costs, and emphasis on diamonds recovered rather than tonnes throughput, positions us well to generate outstanding returns for our shareholders when mining commences from the UK4 Block in the first half of 2015.”

DiamondCorp, which owns the Lace dia-mond mine near Kroonstad in the Free State, says – in its interim results for the six-month period ended 30 June 2014 – that capital expenditure on underground development and mine infrastructure, at the Lace pro ject totalled R76,8 million (£4,3 million) for the reporting period.

A revised development budget and schedule has been adopted for the project which will allow underground kimberlite mining to commence from the high-grade Upper K4 (UK4) Block in the first half of 2015, six months ahead of schedule.

During the reporting period the Lace processing plant operated on tailings primarily so that it could be maintained and optimised in readiness for kimberlite processing, including the UK4 bulk test. Accordingly, income from diamond sales for the period was capitalised as a credit to mine development.

Diamond recoveries from tailings for the period totalled 13 055 carats at an

www.bwep.co.za

September 2014MODERN MINING19

MINING News

Paragon Diamonds gets new ChairmanParagon Diamonds Limited, the AIM-quoted company with dia-mond projects and properties in Lesotho, Botswana and Zambia, has announced that Obtala Resources, the holder of £1 996 000 of loan notes in the company, as well as 27,33 % of the company’s issued share capital, has entered into an agreement to sell the notes to Titanium Capital Investments for a total consideration of £998 000.

Further to this agreement, Paragon has appointed Philip Falzon Sant Manduca (above), as a representative of Titanium Capital, to the board as Executive Chairman. Martin Doyle, currently Executive Chairman, will continue as a non-executive director.

“I am delighted to be joining Paragon Diamonds at a time when production is on course to commence in the near term at our 80 %-owned Lemphane kimberlite mine, which is located close to the world-class Letseng pipe in Lesotho,” comments Sant Manduca. “I am assuming the responsibility to procure for Paragon Diamonds its funding needs in both Stage 1, and within two years, Stage 2 of its development of the Lemphane mine, whilst concurrently explor-ing further options, including the company’s assets in Botswana and Zambia, that can accelerate Paragon’s revenue profile.”

Stage 1 production will cover a two-year period during which approximately 1 Mt of kimberlite will be mined and processed out of the currently estimated 48,6 Mt of kimberlite (to 350 m depth) at the site, using a 75 t/h processing plant. Stage 2 will see production ramped up to 3 Mt/a with peak production expected to hit 65 000 carats per year of high value diamonds.

As part of the debt funding for the Boikarabelo coal project in the Waterberg, Resource Generation has signed a loan facility of up to US$113 million for the mobile equipment fleet for the project with Komatsu Financial Limited Partnership. The term is for five years from the first utilisation date. Resource Generation will be purchasing the equipment from Komatsu Southern Africa.

There are a number of conditions precedent for the loan including signing of the sale agreement for the equipment, registration of secu-rity over the equipment and the signing of the balance of the debt required to complete project construction.

“This agreement represents several important elements for the project,” says Paul Jury, MD of Resource Generation. “It not only secures the funding required for the mining fleet for stage one of the Boikarabelo mine development but also establishes a key partnership for further mine expansion to occur. The transaction clears the way for final infrastructure designs and refines training and maintenance processes. In addition, it provides clarity in relation to negotiations for remaining debt.”

Stage 1 of the mine development at Boikarabelo targets saleable coal production of 6 Mt/a. First coal production is expected in the first half of 2016.

Komatsu to supply Boikarabelo mobile equipment fleet

COVER STORY

20MODERN MININGSeptember 2014

Clive Richardson, Senior R&D Man-ager of Hansen + Genwest, be-lieves the development of the new transformer – undertaken in close collaboration with the customer –

is a major achievement for the company. “As far as I’m aware, we are one of only two com-panies worldwide to offer this technology and certainly this is the first such unit to be both designed and manufactured in South Africa,” he says. “We’re expecting healthy demand from the local underground coal mining in-dustry for this transformer and virtually all the mining houses will be looking closely to see how it performs in its first application. We’ve also received international interest and we al-

ready have one export order in the pipeline.”Explaining the need for the new transformer,

Richardson makes the point that the size and weight of flameproof transformers for the coal mines have steadily increased over the years. “Hansen + Genwest is one of the leaders in the manufacture and supply of dry-type transform-ers, either flameproof or non-flameproof, for the mining industry and has been manufacturing them here in South Africa since the 1970s,” he says. “The first flameproof units were rated at 400 kVA but we’re now up to 2,5 to 3 MVA. As the rating goes up, so too does the weight of the machines and this has now become a major issue for the mines, as it is very dif-ficult to move high-capacity units of this type

Hansen + Genwest launches gas-filled mining transformer

Hansen + Genwest (previously Kopex Africa) has designed and manufactured a gas-filled flameproof mining transformer which it believes is a revolutionary product in terms of the weight savings it will offer customers. The first unit has already been handed over to a coal mine in the Secunda area and two further

units will be delivered to the mine – which is part of a mining group which ranks as one of Hansen + Genwest’s biggest customers – within the next few weeks.

The gas-filled flameproof mining transformer receives the final touches at Hansen + Genwest prior to delivery to site.

Nico Roets, MD of Hansen + Genwest.

COVER STORY

September 2014MODERN MINING21

Another view of the gas-filled transformer. It is 9,5 tonnes lighter than a similarly rated conventional transformer.

Hansen + Genwest’s modern factory is located in Apex, Benoni.

underground. Additionally, the ground-bearing pressures they exert can be problematic.”

Rated at 2,5 MVA, the new transformer has a dry-type design and is enclosed in a hermet-ically-sealed, positively pressurised gas-filled enclosure rather than a normal flameproof enclosure. The gas used is nitrogen, which is inert. “The nitrogen does several things,” Richardson explains. “It acts as both an insula-tion and cooling medium and it also prevents the ingress of gas – methane, for example – into the unit, thus eliminating the risk of arc explosions. Most significantly, though, it allows a dramatic weight reduction – a simi-larly rated conventional transformer would be 9,5 tonnes heavier.”

Richardson notes that the new unit is replacing two transformers at the mine which has ordered it. “Typically, to power a con-tinuous miner section they’ve been using two 1 250 kVA transformers and an associated bank of switchgear. Part of the reason for two units is that there are normally two separate power or voltage ratings required in a continuous miner section. One of the transformers would supply the continuous miner – which needs 3,3 kV – and the other all the related equipment, which runs on 1 000 V. Our new machine will cater for both these needs.”

This first machine represents phase one of a three-phase development cycle. “Currently the unit needs a trailer with switchgear and this will be eliminated in phase two while in phase

three we will make the unit self-powered, thus obviating the need for a prime mover. Once we reach this stage – which we should achieve by the middle of next year – our gas-filled trans-former will have the ability to replace not just two separate transformers but also the trailer with switchgear and the prime mover. Looked at in this light, the weight saving will be even bigger – overall about 44 %.”

Richardson stresses that the transformer complies with all applicable international standards, notably IEC 60079, Part 2 and IEC 60076.15.

Moving on to the change of name from Kopex Africa to Hansen + Genwest, MD Nico Roets says the company is simply adopting the name

www.miningindaba.com

COVER STORY

September 2014MODERN MINING23

that it used to have up until 2010. “The change makes sense since our customers still associ-ate us with the Hansen + Genwest name and will often tell us they want a Hansen + Genwest transformer,” he observes. “It’s a strong brand. In addition, the name associates us with our holding company, Hansen Sicherheitstechnik AG of Germany, which, in turn, is a subsidiary of the international Kopex group.”

Roets stresses that, apart from the name change, everything else stays the same. “Our ownership, our management, our location on the East Rand and our product range remain exactly as they were. Customers can be assured that they are dealing with the same company as always.”

While the Kopex Group internationally is emerging as an important global supplier of a wide range of mining equipment including longwall systems, conveyors, stacker-reclaim-ers, shuttle cars and pumps, the South African operation remains highly focused on dry type transformers together with associated switch-gear and distribution equipment such as load centres, gate-end boxes and intrinsically safe protection relays.

The transformers – which offer a high level of energy efficiency – range in capacity from 50 kVA to 10 MVA while some of the company’s other products are of formidable size. Gate end boxes, for example, are up to 9 m in length, can weigh as much as 16 tons, and offer as many as 20 power outlets. Hansen + Genwest has also recently designed and manufactured a 10 MVA sub-station skid for use in an open pit to supply power to draglines which weighs up to 50 tons.

Hansen + Genwest’s transformers are sub-ject to what is known as ‘type testing’ in which new designs are tested to near destruction.

According to Roets, the company is one of the few suppliers that undertake this type of testing, which is very expensive and time consuming. “Notwithstanding the cost and time involved, we believe it is essential as it gives our custom-ers the assurance that the product they have bought will perform exactly as we say.”

In an interview earlier this year with Modern Mining, Roets remarked that the Hansen + Genwest transformer could be viewed as a ‘Rolls Royce’ product. “It is built by hand to the customer’s exact specification,” he said at the time. “We don’t use machines and robots, as many overseas manufacturers do, because this approach generally results in inferior qual-ity. Of course, if you manufacture by hand, you need skilled, experienced employees – your workforce is absolutely crucial. We have these people and indeed many of them have been with us for over 10 years. We also have a full engineering and R&D capability and the depth of expertise in this department is probably unmatched in South Africa.”

Cores are manufactured from special, indi-vidually insulated plates of sheet metal to stringent standards while the windings consist of high-quality insulated copper conductors. The coil construction is separated by segments for cooling and supported by insulating spac-ers. The MV and LV coils are impregnated with a silicone resin to ensure a solid construction with high moisture resistance.

Apart from manufacturing new machines, Hansen + Genwest also offers a full recondition-ing service which can bring aged machines to an ‘as new’ condition. Refurbishment currently accounts for around 15 % of the company’s business but there are plans in place to grow this figure to 30 %.

Left: Refurbishment current-ly accounts for around 15 % of the company’s business. Seen here is a gate-end box awaiting reconditioning.

“Our ownership, our management, our location on the East Rand and our product range remain exactly as they were.”

Nico Roets, MD, Hansen + Genwest

DIAMONDS

24MODERN MININGSeptember 2014

Considering the challenges it has faced since acquiring the project, Gem Diamonds (Gem) can con-gratulate itself on having achieved the near impossible with respect

to Ghaghoo. Its achievement is all the more noteworthy given that the timeline from the acquisition of the property to first production has been just seven years – a period, moreover, which saw the greatest mining boom in his-tory coming to an inglorious end in September 2008 with the collapse of global financial and commodity markets.

In his speech at the opening, Clifford Elphick, Gem’s CEO, recalled the effects of the Global Financial Crisis (GFC), as the event has come to be known. “Let me remind you that there was absolutely no capital available from financial institutions, banks or the investment community to fund any mining projects any-where in the world,” he said. “This meant we had to innovate, ration capital and think

Gem triumphs in the Kalahari

Clifford Elphick (left), Gem’s CEO, shakes hands with the President, Lieutenant General Seretse Khama Ian Khama, at the unveiling of the plaque commemorating the opening of the mine.

Night view of the processing plant, with final recovery building on the left.

Gem Diamonds Limited, listed on the LSE, seems to have an affinity for extreme environments. Its flagship Letšeng mine in Lesotho, located at an elevation of 3 100 m in the Maloti Mountains,

is reputedly the world’s highest operating diamond mine while its new Ghaghoo mine is situated in the Central Kalahari Game Reserve of Botswana in one of the most remote areas of Southern

Africa. Ghaghoo – which ranks as Botswana’s first underground diamond mine and which exploits a kimberlite (GO25) buried under 80 m of Kalahari sand – was officially opened on 5 September

by Lieutenant General Seretse Khama Ian Khama, Botswana’s President. The function on site was attended by around 120 guests, including Modern Mining’s Arthur Tassell.

DIAMONDS

September 2014MODERN MINING25

creatively and differently. It was never an option to simply walk away because the prob-lems were seemingly insurmountable.”

The GFC led to the project – acquired by Gem in 2007 from De Beers and Xstrata, the joint owners, for US$34,1 million via an auc-tion process – being put virtually on hold for two years. Gem had originally envisaged devel-oping a large 6 Mt/a open-pit operation at the site able to produce in the region of a million carats a year. The predicted capex was formi-dable – around half a billion dollars with the costs of the massive pre-strip exercise alone being estimated at US$250 million. Clearly this approach was no longer viable in the post-2008 financial environment and the project team started to look at plans to bring the project into production on a far more modest scale with the goal being a total capex of just US$96 million

– the amount that Gem could afford without recourse to the markets.

By the end of 2010, the project team had a plan in place. It had decided that Ghaghoo could be developed as an underground mine. Initial production would be much smaller than the open pit with 60 000 tonnes per month (tpm) being targeted (to produce between 200 000 and 220 000 carats a year) but with further phases of expansion envisaged to opti-mally exploit the 20,53 million carat resource (at an average grade of 19 cpht). The thinking was – and this has not changed since – that the first phase would be very much a ‘proof of con-cept’ aimed at confirming diamond grades and prices and testing mining methods and process-ing techniques.

Gem’s board approved the capital budget for construction of Phase 1 of the mine in March

Miners making their way out of the mine after a long day underground.

Pictured here (left to right) are three of the key figures associated with the project from Gem Diamonds Botswana: Haile Mphusu, MD of the Botswana company; Ian McAdam, Project Manager, Gem Diamonds Botswana; and Kavis Kario, GM, Ghaghoo diamond mine.

DIAMONDS

26MODERN MININGSeptember 2014

Above: The decline showing the concrete segment lining of the ‘sand tunnel’ portion.

Right: Safety briefing in the decline.

2011. At very much the same time, the pro-ject, originally known as ‘Gope’, was renamed ‘Ghaghoo’, the local word for the thorn of the umbrella thorn acacia tree, which is abundant in this particular part of the CKGR.

Once the decision was taken to proceed with an underground mine, the next big chal-lenge was how to drive the 1,2 km long decline accessing the orebody through approximately 80 vertical metres of unconsolidated Kalahari sand. Various methods were looked at by the team and eventually it was decided to employ a hydraulically operated open-faced tunnel shield (OFTS) as the “front line mining tool” (to use Gem’s words). Weighing more than 100 tonnes, the OFTS was used to place the thou-sands of concrete segments required to line the so-called ‘sand tunnel’ portion of the 8 deg decline extending over a distance of 473,3 m. In all, there are 763 rings each consisting of 10 concrete segments.

Referring to the use of a shield in his address, Elphick said that Gem had found a way to access the orebody using techniques which were effective and economic. “This will open up many other opportunities in this coun-try particularly and probably in Angola too,” he told guests at the opening. “There are a number of similar orebodies covered by Kalahari sand which will now be looked at differently – the truth is here before our eyes – and not just for diamonds; already this method has been con-sidered for a copper deposit in Botswana.”

While Redpath Mining was contracted to develop the sand tunnel, the remaining portion

DIAMONDS

September 2014MODERN MINING27

The presidential aircraft arrives at Ghaghoo for the official opening.

of the decline through basalt was undertaken in house by Gem after removal of the shield in July 2013. The kimberlite orebody was inter-sected in November last year on Level 0 at 134 m below surface and in May this year kim-berlite was intersected in the first production level, Level 1 (154 m below surface).

As regards the processing plant (designed and built by Consulmet of Johannesburg), this too has seen a degree of innovation with the incorporation of an autogenous (AG) mill, only the second in Botswana (the first is at Lucara’s new Karowe mine near Orapa) and one of only a handful of such units in Africa. The use of AG milling – in which the ore grinds itself, so to speak – reduces the downstream plant size and enables better liberation with greater recov-ery of fine diamonds. It also reduces the risk of breakage of large diamonds. The 138-tonne mill was designed by South Africa’s Harcliff Engineering (although most of it was manufac-tured in China).

Apart from the AG mill, other elements of the plant include a 100 t/h primary crusher, a 65 t/h DMS module and a recovery section that uses wet X-ray machines (manufactured by Flow Sort) and a grease belt scavenger unit. Interestingly, the plant was completed ahead of the underground works and placed on care and maintenance at the end of 2012. Work on taking it out of mothballs started in November last year and in April this year it treated its first kimberlite.

In another innovation which has saved time and money, Gem – which initially intended to provide ventilation for the underground mine

via a 6 m diameter ventilation shaft – has instead elected to drill three ventilation holes, each between 1,1 m and 1,2 m in diameter. All three have now been completed by De Wet Drilling – based near Gaborone – using its famous large diameter Elephant drill. These ventilation holes will also function as emergency exits and two have already been fitted with equipment simi-lar to that used to rescue the trapped Chilean miners in 2010. The emergency equipment will allow a capsule to be lowered into an under-ground chamber from where the miners can be transported to surface one-by-one.

The Ghaghoo mine is now in its ramp-up phase and by the end of June this year 2 400 carats had been recovered – during commis-sioning of the plant – including a 20-carat and two 10-carat diamonds. These large stones compare favourably to the largest diamond (7 carats) recovered during the exploration sampling phase. A workforce totalling roughly 60 people is deployed in the underground mine (over three shifts) and the mining method used is sub-level caving. The mechanised fleet – comprising three trucks, two LHDs and three drill rigs – has been supplied by Atlas Copco.

Three production tunnels are currently pro-gressing in the kimberlite on Level 1 whilst an exploratory tunnel and training stope have been developed in the kimberlite on Level 0. Eight production levels are ultimately planned and will be developed 20 m apart. The full Phase 1 production target of 60 000 tpm is planned for 2015.

In terms of power, Ghaghoo is a fairly mod-est user of electricity – which is just as well,

The use of AG milling – in which the ore grinds itself, so to speak – reduces the downstream plant size and enables better liberation with greater recovery of fine diamonds. It also reduces the risk of breakage of large diamonds.

www.servest.com

DIAMONDS

September 2014MODERN MINING29

Logistics obstacles overcomeNo account of Ghaghoo would be complete without a brief mention of the huge logistics problems that had to be faced. The site lies at the end of a 160  km long sand track running from the logistics staging post set up at Lephepe at the end of the asphalt road from Gaborone. Loads at this point were transferred from normal trucks onto heavy-duty, multi-traction ve-hicles able to negotiate the thick Kalahari sand. The logistics function was contracted out to CCB, which also built the camp infrastructure.

The autogenous (AG) mill, only the second of its type in Botswana (photo: Arthur Tassell).

since a connection to Botswana’s grid would be prohibitively expensive. Currently an on-site power facility based on diesel gensets supplies up to 6 MW of power and is run by Aggreko. Briefing journalists prior to the mine opening, Elphick said Gem was looking at also install-ing solar power generation to work in tandem with the gensets. Gem believes that solar power could supply up to 60 % of the mine’s electric-ity needs.

Environmentally, Ghaghoo is in an extremely sensitive area – it is the first mine in Botswana within a game reserve – and Gem is taking great care to ensure that its impact is reduced as far as possible. The decision to go underground rather than develop an open pit – although dictated by economics – has obvi-ously been a major plus environmentally as it limits the footprint of the mine. Over and above this, Ghaghoo will be using the Australian ‘fly in-fly out’ model for its more its senior employ-ees (with no families allowed). In general, there are only a limited number of permanent struc-tures on site – employees live in a tented camp – and these are mainly of a prefab nature, mean-ing that they can easily be disassembled and removed at the end of mine life. Camp man-agement, incidentally, is in the hands of CMSB, which is owned by Servest.

Water, surprisingly, is not a huge problem – groundwater is relatively plentiful in the area – but the process plant has nevertheless been designed to be an economical consumer of water (using only 0,75 m3 per tonne of ore processed, which is below the figure for most processing plants in the diamond mining industry).

Commenting recently on the environmen-tal challenges, Haile Mphusu, MD of Gem Diamonds Botswana, had this to say: “Our success or failure is not only about our mine, but about the concept of mining in a protected area. We are pioneers here. Our impact on the environment will determine the future of other CKGR deposits that are currently being explored.”

Ghaghoo’s isolated location in the CKGR means that there is no community of any size close to the mine – other than a single extended Basarwa (San) family living in three settlements adjacent to the property. Gem did, however, consult extensively with the wider Basarwa community of the CKGR during the planning phase of Ghaghoo and has already collaborated with an NGO to assist in providing local com-munities with access to water. Additionally, the company has established a Community Trust, which includes two trustees from the project-affected communities and which has already

started on implementing community projects identified in a collaborative needs assessment process.

Finally, it is probably worth mentioning that the building of a new mine in the Kalahari has not been without its critics, notably Survival International, an NGO, which has accused the Botswana government of a “relentless push to drive the Bushmen out of the reserve” in order to clear the way for diamond mining. The President, Lieutenant General Seretse Khama Ian Khama, refuted these accusations at the opening ceremony. “It would be remiss of me if I did not mention that this mine has been a subject of various controversies, driven by deliberate disinformation by some elements bent on tarnishing our country’s image just because they differ with our approach to devel-opment,” he said. “I want to reiterate that our government has and always will put its people and the preservation of the environment first in whatever developmental initiatives we under-take and the development of Ghaghoo diamond mine is not an exception.”

Photos courtesy of Gem Diamonds (unless otherwise acknowledged)

GOLD

30MODERN MININGSeptember 2014

In 2013, Galane carried out an exercise to review the potential of screening its low grade stockpiles. The results of this exercise and related test work in respect of the previously disclosed measured

mineral resource at the Mupane stockpiles in-dicated that there are 702 259 tonnes of low grade stockpile – at an average grade of 0,97 g/t

Galane Gold (Galane), listed on the TSX-V, has commis-sioned a new screening plant at its operations in Botswana,

which are centered on the Mupane gold mine, located 30 km south-east of Francistown. It also announced earlier

this year that the transition at Mupane from open-pit to un-derground mining had passed a milestone with the mining

of the first ore from Tau Underground.

Galane Gold commissions screening plant at Mupane– located at the run-of-mine (ROM) pad at the processing plant. Screening the ore using a 40  mm screen deck is expected to increase 38 % of the stockpile grade by 65 % with the upgraded ore reporting to the minus 40 mm product size fraction.

The process is expected to produce an addi-tional 266 858 tonnes of ore at an average grade of 1,60 g/t to feed the processing plant. The screened material is expected to have a recov-ery rate of 83 % and – as it is predominantly oxide in nature – the milling rate will, it is anticipated, increase by 20 % due to the size and nature of the material. The direct operat-ing cost per ounce is forecast to be in the range of US$600 to US$700. In addition, Galane is reviewing a further 1,4 Mt of low grade stock-piles, not previously reported, to ascertain if

GOLD

September 2014MODERN MINING31

Night view of the new screening plant at the Mupane site.

Layout of the Tau pit and the underground mine.

they can also be treated in the same way. The screening plant is fed from the ROM

pad by direct tipping and feeds the processing plant crushed ore stockpile. Galane intends to feed the low grade stockpile over the next three years, as required, to complement its other sources of ore. In addition, the screening plant will be used to process low and sub grade ore mined at the company’s other opencast pits.

The US$295 000 capital cost for the acquisi-tion and construction of the plant was funded from the company’s operating cash flows.

“The commissioning of the screening plant is an important part of our current five-year plan and a key component of our ongoing effort to decrease production costs,” comments Galane’s Chairman, Ravi Sood. “This represents a testament to the experienced and innovative

Galane Gold commissions screening plant at Mupane

www.weirminerals.com

GOLD

September 2014MODERN MINING33

The portal of the underground mine (Tau Underground). The portal is 5 m high by 4 m wide but this reduces further in to 4 m x 4 m.

management team we have put in place and their commitment to making Galane a long mine-life, low-cost producer.”

As regards Tau Underground, this is exploit-ing a measured and indicated resource of 128 600 ounces of gold. Galane commenced the project in the fourth quarter of 2013 and earlier this year completed the forced portal entry at the bottom of the existing Tau pit, installation of the entire infrastructure required, appoint-ment of an underground contractor and the development work required to reach ore.

The company has put together a mine plan based on the reported resource to mine approx-imately 85 000 ounces of gold over the next three-and-a-half years. The mining method being used is long hole open stoping.

“This is a major step in the evolution of the company both with regards to a change from open-pit mining to underground mining and our plans to extend mine life through further explo-ration,” says Sood. “We are also putting together a mine plan to connect all the current pits on the Mupane mining licence underground, as for example we know that mineralisation continues at depth at Tholo and Kwena.”

The mining contractor selected by Galane is S&B Mining Consultants, run by Steve Venn. Based in South Africa, S&B’s senior manage-ment has over 100 years of mining experience and is particularly skilled at mining the green-stone gold deposits found in Zimbabwe, the Barberton area of South Africa, and Botswana. The company has partnered with equipment supplier Minetech, based in Francistown, enabling it to supply a range of machines to Mupane, including drill rigs and low profile dump trucks.

Galane’s assets in Botswana – acquired from IAMGOLD in 2011 – cover the Tati greenstone belt and extend mainly to the south-east and west of Francistown. Apart from Mupane, they include the Signal Hill, Golden Eagle and Jim’s Luck deposits, all within trucking distance of

the modern – it was commissioned in 2004 – CIL plant at Mupane which has a nameplate capacity of 1,2 Mt/a of oxide ore and 1 Mt/a of sulphide ore.

In 2013 the company – which operates in Botswana through its subsidiary, Mupane Gold Mining (Pty) Ltd – produced 38 754 ounces of gold but its goal, in terms of its five-year plan for Mupane and the related assets, is to produce consistently at 50 000 ounces a year at an all-in cash cost of approximately US$1 100/oz.

Apart from Ravi Sood, who is based in Canada, Galane’s management team includes Charles Byron, Chief Geologist and Director, who led the team that discovered the Mupane deposit in the late 1990s, and Wayne Hatton-Jones, General Manager, who has 26 years’ experience in mining with companies such as Galaxy Gold (where he was COO), Randgold, Harmony Gold, Mintails and DRD. Apart from his extensive African experience, he has also worked overseas in Tajikstan, Uzbekistan, the Philippines and Romania. Byron and Hatton-Jones are both based in Francistown.

In its recently announced second quarter results (to June 30, 2014), Galane reported that it produced 7 196 ounces of gold at an operat-ing cash cost of US$1 201 per ounce (excluding royalties) during the quarter. Total ore mined was 137 114 tonnes at an average grade of 1,92 g/t (including 3 384 t of ore from Tau Underground at 2,85 g/t). Total ore milled was 181 011 t at a head grade of 1,85 g/t.

The results were negatively impacted by the failure of the SAG mill motor during May 2014. Although the company installed a smaller spare motor, the milling capacity was restricted to 70 % of normal capacity. A new SAG mill motor has now been commissioned, leaving the company – according to Sood – in a strong posi-tion to meet its financial and production targets for the year. Galane has repaired the faulty mill motor which will be stored on site as a spare.Photos courtesy of Galane Gold

Galane’s assets in Botswana – acquired from IAMGOLD in 2011 – cover the Tati greenstone belt and extend mainly to the south-east and west of Francistown.

34MODERN MININGSeptember 2014

COPPER

Construction activities at Sentinel maintained peak pace and, at the end of the June quarter, the pro ject passed 21,5 million man hours worked. Milestones included

131  000 m3 of concrete poured; 98 % of the project steel on site, with 89 % of the site steel erected; and completion of the erection of all four mills and mill drives. The Chisola raw water coffer dam and inlet water pipelines have been completed and the raw water line to the plant site is being commissioned.

Zambia’s Sentinel copper project all but complete

In its latest quarterly report, Toronto- and London-listed First Quantum Minerals (FQM) says that its Trident project (comprising the Sentinel copper mine and Enterprise nickel mine) in Zambia is continu-ing to make good progress with Sentinel, the more advanced and bigger development, 94 % complete

as at the end of the quarter (30 June). With an anticipated production of between 270 000 and 300 000 tonnes of copper metal in concentrate annually, Sentinel will rank as one of the biggest copper mines

in Africa. It is located approximately 150 km west of Solwezi in the north-west of Zambia.

Commissioning of process plant equip-ment, including thickeners, flotation cells and potable water systems, is underway. Construction disciplines are fully engaged with the commissioning effort on site. Housing and infrastructure works are 95 % complete, according to schedule. Mining fleet assembly is progressing well ahead of schedule and was 99 % complete as at the end of the quarter. The first in-pit crusher was scheduled to undergo dry commissioning early in Q3 2014.

Power transmission line works continue

September 2014MODERN MINING35

COPPER

to support the crusher and mill commission-ing activities. This will allow continuous operation of the first milling train by Q4 2014. Construction works are in progress on the lon-ger powerline to Lusaka West and Mumbwa for the supply of the full electrical demand at Sentinel, and the contracted completion date for this section is the end of 2014.

Sentinel continues to perform strongly on its capital cost and schedule targets, says FQM. Capital cost is estimated at US$1,9 billion, and the target completion date is unchanged

Above: A Cat 7495 electric rope shovel being assembled at Sentinel. It is equipped with a 57 m3 bucket. The mine will have three of these machines which will mainly be used for waste stripping but which will also operate in ore from time to time. Each unit weighs 1 350 tonnes.

Above left: A view of the Sentinel site as it was in early July this year.

The Sentinel mine primary crushing facilities comprise three 20 Mt/a ThyssenKrupp KB 63-89 gyratory crushers. One of the installations is seen here.

with partners ZESCO Limited and FQM’s construction contractors. Stringing of the pow-erline conductors from the Lumwana mine has progressed well and will provide the first 90 MW of power to the site during Q3 2014

www.mmdsizers.com

September 2014MODERN MINING37

COPPER

with staged commissioning of milling scheduled to commence from Q3 2014.

Environmental approval for the Enterprise nickel mine, located approximately 12 km north-west of Sentinel, is under application. Engineering design is complete, the SAG and ball mill foundations are complete and the mechanical erec-tion of the SAG mill is underway. Concrete works for the stockpile feed conveyor vault are well-advanced with supporting earthworks under-way. Construction is scheduled to be completed in early 2015, with commissioning during the year. The processing plant area under construc-tion for future Enterprise ore will be commissioned and run on Sentinel ore until the Enterprise mine is approved.

On its copper smelter complex project at Kansanshi in Zambia, FQM says that during 2013 it undertook a detailed study of local copper smelter capac-ity in light of its growing copper production in Zambia. The study identified technical, operational and economic benefits of expand-ing the smelter facilities by over 65 % into a complex capable of processing 2 Mt/a of cop-per concentrate. While planning and scoping of the expansion are in the early stages, con-struction is being contemplated to follow the commissioning of the Phase 1 smelter currently underway.

The Phase 1 smelter of the complex is designed to process 1,2 Mt/a of concentrate to produce over 300 000 tonnes of copper metal annually. It is also expected to produce 1,0 Mt/a of sulphuric acid as a by-product which will benefit Kansanshi by allowing the treatment of high acid-consuming oxide ores and the leach-ing of some mixed ores. The additional acid is expected to optimise the expansion of the oxide leach facilities and allow improved recoveries of leachable minerals in material now classified and treated as mixed ore.

With detailed design work completed, and essentially all equipment and materials on site, the focus is on site construction and par-allel commissioning activities to advance the completion schedule on two shifts. Site con-struction remains at peak pace with strong progress of around 8 % per month being achieved in May and June, and the project achieving 78 % overall completion. While construction completion is expected during Q4 2014, initial commissioning activities were started in July, and will likely continue for

The Phase 1 smelter at Kansanshi – strong acid and converter area.

several months. At completion, it is anticipated that capital expenditure for Phase 1, together with some infrastructure and components shared with the eventual expansion to 2 Mt/a, will total approximately US$850,0 million.

Commenting on the second quarter results, Philip Pascal, FQM’s CEO and Chairman, said the second half of 2014 would be an important one for the Group. “Both the Phase 1 copper smelter and Trident project are tracking well for staged commissioning during this period towards commercial operations in 2015. These are significant components in the compa-ny’s growth and, when in operation, they are expected to employ an additional 2 400 people, add up to 300 000 tonnes of new copper pro-duction capacity and enhance the overall unit operating cost.”

While FQM has copper and nickel mining operations in Mauritania, Australia, Finland, Turkey and Spain, its biggest single operation at present is Kansanshi, which is Africa’s largest copper mine and which is expected to produce between 255 000 and 270 000 tonnes of copper in 2014 (as well as between 150 000 and 160 000 ounces of gold). Apart from Trident, the Group is also busy developing the massive US$6,4 billion Cobre Panama open-pit copper project, located 120 km west of Panama City in Panama, which is expected to commission in the second half of 2017. Designed for an initial 70 Mt/a capacity (approximately 320 000 t/a copper), the mine will also have significant by-product production of gold, silver and molybdenum.Photos courtesy of First Quantum Minerals

Environmental approval for the Enterprise nickel mine, located approximately 12 km north-west of Sentinel, is under application.

38MODERN MININGSeptember 2014

COPPER

The current contract involves all horizontal development work us-ing trackless high speed technol-ogy in Ramps 1, 2, 3, 4 and 5. The Murray & Roberts Cementation

team was also requested to undertake the ver-

tical development of return airways, service raises and silos. Maintenance work on the surface infrastructure, provided by Murray & Roberts Cementation on the first phase of the contract, will continue for the duration of the entire contract.

“In addition, we will continue the develop-ment of infrastructure for two conveyor belt systems and supply and install all temporary compressors and air piping reticulation neces-sary for the development works and diamond drilling section. Furthermore, we will install all temporary ventilation fans and ducting,” says Wyllie Pearson, Murray & Roberts Cementation Senior Project Manager at Lubambe.

“We also operate and maintain the owner’s

Development contract at Copperbelt mine extended

Diamond drill operation at Murray & Roberts Cementa-tion’s Lubambe contract.

Murray & Roberts Cementation’s second contract, for the trackless high speed development at Lubambe Copper Mine in Zambia, has been extended for a further two-year period.

Lubambe Copper Mine is a joint venture between African Rainbow Minerals, Vale and Zambia Consolidated Cop-

per Mines Investment Holdings and is expected to produce 45 000 tonnes of contained copper at steady state by 2015.

September 2014MODERN MINING39

COPPER

A twin boom roof bolter in operation at the mine.

equipment fleet – six Sandvik TH 540 dump trucks, four Sandvik LH 410 LHDs and one Sandvik LH 514 LHD, as well as nine Sandvik TH540 40-ton articulated dump trucks allocated to load and haul. Face charging is performed with three Getman emulsion charging units and the transport and lifting equipment consists of two Getman scissor lifts, a Fermel scissor lift and two Getman cassette handlers. A Fermel grader and Manitou 742 telehandler complete this fleet,” says Pearson.

Allocated to drilling are five Sandvik DS320 double boom split-feed jumbos, a DS320 fixed rail jumbo and a DS420 long hole rig used for raise mining. The support and supervision vehicles are Toyota Land Cruisers, which have been converted to mining specifications.

“All maintenance work on this equipment as well as the Murray & Roberts Cementation equipment fleet is undertaken in our well-equipped on-site workshop by a highly experienced team of mechanics and techni-cians to ensure optimised operability and uptime. All consumables are supplied by the mine,” he adds.

Pearson says the contract is characterised by

a high level of cooperation between the Murray & Roberts Cementation and Lubambe Copper Mine teams. “We have developed a mutually beneficial relationship that sees us providing our client with a ready and continuous supply of power and water handling facilities to ensure efficient interaction within overlapping areas. In addition, the mine provides our team with rock bolts, split sets, mesh and cement, while diesel and lubrication oils are supplied as free-issue items.”

Since the extension of the first contract by 15 months, a total of 24 653 m has been developed against a target of 23 458 m. “We have made excellent progress to date and met every one of our scheduled targets. The two main under-ground tipping arrangements consisting of four tipping points and two silos were completed and commissioned within the scheduled con-struction dates. A mineral sizer was installed and commissioned ahead of schedule on the tips,” says Pearson.

The six-level crusher chamber was reha-bilitated and supported with welded mesh and 6 m cable anchors, with the crusher and equip-ment in place. In order to assist with the main

40MODERN MININGSeptember 2014

COPPER

return air system, a series of ventilation raises were developed from the ramp at 3 225 Level and two 225 kW surface fans installed and commissioned.

The project has not been without its chal-lenges. Some parts of the Lubambe orebody can only be accessed by mining through a very weak zone of sand-like material. The sand zone developing and support project comprises four successfully completed sections with a fifth in progress. These sand zones require specialised support methods developed specifically for Lubambe and are similar to civil tunnelling support methods. Pearson explains that this has been effectively achieved by using Titan soil nails, Becker arch sets, 5,6 mm welded mesh and shotcrete as support mediums. Sand is excavated out of the face using a Hyundai 35Z7 mini excavator.

At the request of the client, a drop raising programme was undertaken, with 12 345 m completed concurrently with contractual development.

Pearson believes that the success of the project to date can be attributed to a number of factors, including the creation of a highly efficient team of experienced and multina-tional operators, supervisors and management, mostly with previous expatriate experience. The drilling team is a mixture of Australian decline mining specialists and Filipino and South African expats.

The team comprises 405 employees, with approximately 12 % of them expatriates. The Zambian national component of the team is made up of HR staff, surveyors, accounts and

administration staff, skilled operators, officials and workmen. The expat component of the crew consists of site management, safety and training staff and expert miners, operators and maintenance staff.

Similarly, training plays a big role in ensur-ing that the requisite regulations and quality standards are achieved and maintained. “The training at Murray & Roberts Cementation’s Bentley Park facilities included trackless mining modules. The nature of the orebodies in Zambia is such that most of the mining is fully trackless, with the exception of the haulage levels. There is a vast pool of fully trained and experienced mine workers available to recruit from, which has greatly simplified the human capital ele-ment of the project,” Pearson points out.

He says that there was a successful trans-formation from a small highly skilled decline sinking crew to a team responsible for ore and main development, sometimes in remote and scattered areas of the mine.

Employees also have access to a modern e-learning centre which has been opened at Murray & Roberts Cementation’s Synclinorium shaft sinking project in Kitwe. “This centre pro-vides the same high quality standards as the Bentley Park facility in South Africa. The com-prehensive Murray & Roberts electronic library and learning system is available for learners and facilitators alike,” says Pearson.

Appropriate and successful training is reflected in the safety record achieved on site, with no Lost Time Injuries (LTIs) recorded for the first year. There have also been no fatal incidents on the contract to date, a noteworthy achievement given the nature of the project.

Pearson believes the award of the Synclinorium shaft-sinking project, as well as the shaft sinking and development of the Mufulira Deeps project, are a true reflection of the company’s reputation in the region. In addition, Murray & Roberts Cementation’s Raise Boring Division is presently operating in Kansanshi, a further indication of the sig-nificant growth in the company’s presence in Zambia.

“Murray & Roberts Cementation has demonstrated complete commitment to its Zambian projects through the formation of a Zambian division with corporate offices situ-ated in Kitwe. We are presently able to offer prospective clients a full shaft-sinking and development portfolio, including training and administration from Zambia, with the benefit of technical and logistical support from Murray & Roberts Cementation in South Africa,” says Pearson.

Loading operation at Lubambe. Murray & Roberts Cementation operates and maintains the owner’s equipment fleet.

The sand zones require specialised support methods developed specifically for Lubambe and are similar to civil tunnelling support methods.

www.flsmidth.com

42MODERN MININGSeptember 2014

BULK MATERIALS HANDLING

According to Keith Dowie, Proj-ect Development Manager for BLT SA’s Samson bulk materials handling equipment, Samson automated handling systems of-

fer reliable performance – from truck intake, using the Samson surface feeder, to mobile stacking and ship loading solutions. “Reliable handling equipment plays a critical role in complex logistic operations required to deliv-er materials on time and to specification, with minimal environmental impact,” he says.

“Economical transportation of coal demands the efficient use of rail, road and sea shipment for long distances, with truck or conveyor haul-age for short runs at the mine or quarry.

“Samson handling equipment is known globally for flexibility, with no compromise on performance, environmental standards, reliability or safety. These systems, which require minimal civil works, are designed to

join together fixed and mobile equipment, pro-viding a cost efficient alternative to fixed bulk handling installations. Operating costs and maintenance requirements are significantly lower than with conventional materials han-dling systems.”

Samson’s Stormajor radial boom stacker combines the benefits of the Samson material feeder unit with a radial outloading boom into a single mobile unit that is able to receive mate-rial from tipping trucks and loading shovels.

The buffer holding capacity of the integral Samson receiving unit enables efficient truck unloading during tipping truck deliveries.

Material is drawn from the tipping truck in a controlled stream, which means dust gen-eration is significantly reduced, minimising environmental pollution.

With the radial boom feature, this fully integrated machine is able to efficiently create economical stockpiles, with minimal machine movements. Using a hydraulic cylinder in tension, a wide angular range may be accommo-dated allowing the boom to be lowered almost horizontally. This system allows material with a low angle of repose to be stockpiled at steep conveyor angles, without material engulfing the main axle wheels. A single machine may be used for different stockpile areas handling

Bulk handling range provides solutions for the mining sector

Samson’s Stormajor radial boom stacker combines the benefits of the Samson material feeder unit with a radial outloading boom into a single mobile unit.

BLT SA supplies a range of robust bulk handling equip-ment and systems – including radial boom stackers and

Eco-hoppers – that provides efficient solutions for the handling of minerals and concentrates in a number of

industries, including the coal mining sector.

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September 2014MODERN MINING43

BULK MATERIALS HANDLING

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BLT SA’s range of Samson bulk materials handling equipment includes travel-ling Eco-hoppers.

different materials, with minimal capital investment.

There are three capacity ranges of the con-veyor, which are based on the belt width of the out loading boom conveyor. A belt width of 800 mm offers a handling rate of 450 m³/h, a 1 000 mm width belt has a 4 750 m³/h rate and a belt width of 1 200 mm offers a rate of 1 250 m³/h.

These units have various specification options suitable for handling different materi-als, from cereals to heavy mineral ores.

Samson material feeders – a flexible and cost efficient alternative to conventional under-ground hoppers – are installed above ground by simply being bolted to a flat concrete slab foun-dation, eliminating the need for truck ramps and costly civil engineering works. Even in fixed installations this portable system can be easily relocated for future plant development.

The Samson range also includes Samson Eco-hoppers which are suitable for discharge by grab cranes and are designed to suit the char-acteristics and flow properties of virtually any bulk material, including coal, iron ore, gypsum, copper concentrates, soda ash and wood chips. “These robust grab unloading hoppers offer handling rates to 5 000 t/h, depending on grab crane performance,” says Dowie.

Eco-hoppers, which are manufactured to withstand tough conditions at ports, also have an effective dust control system that minimises the escape of dust during the grab discharge cycle. Environmental pollution caused by fugitive dust is a major problem in dry bulk handling.

The hoppers have an upper and lower sec-tion, separated by a dust retention feature, the ‘Flex-Flap’. This divider, which comprises a series of pressed steel sections and vertical rubber flaps, opens to allow the free flow of material into the hopper and closes to prevent the flow of air out of the hopper.

When bulk material is released by the grab, it falls through the Flex-Flap and accumulates in the inner hopper below. The hopper system automatically closes as a result of the newly cre-ated pressure differential between the hopper and the atmosphere, forming a seal to contain the dust contaminated air. Integral reverse jet filters are positioned around the hopper inlet to extract and clean the dust laden air. Collected dust is then re-cycled into the mainstream of material.

The Flex-Flap feature reduces the volume of exhausted air necessary to control fugitive dust and requires the use of small, compact filters rather than a large de-dusting system.

The standard Samson Eco-hopper series includes circular hoppers, which are designed to accommodate grab capacities between 1 and 37 m³. Each hopper size has a corresponding high or low level framework, depending on the chosen discharge option.

Custom-designed hopper solutions that suit specific application requirements are also available.

Eco-hoppers can be rail mounted or bolted to suitable concrete foundations. For applications requiring a higher level of manoeuvrability, hoppers can be supported on solid rubber-filled pneumatic tyres. The combination of fixed and steering axles provides the option of power travel.

Heavy lift in MozambiqueWhat is reported to be the heaviest lift executed on a mining project in Mozambique was made possible after twelve months of planning by Kentz Engineers and Constructors Ltd working on the Kentz Moatize Expansion: Nacala Port (MENP) project.

The team designed and built the critical erection trestle to support the 750-ton-Liebherr crane that lifted into place a 250-ton ‘wagon tippler’. It will

off-load double train wagons carrying 130 tons of coal and is capable of han-dling 18 Mt/a of coal.

www.sew.co.za

September 2014MODERN MINING45

BULK MATERIALS HANDLING

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Need for new thinking around transfer pointsThe application of transfer chutes is central to any opera-tion in the bulk materials handling industry. The mining sector, in particular, presents a number of challenges due to the nature and volume of the material being transferred from one point to another.

Weba Chute Systems control material movement in such a way as to match the prod-uct discharge velocity with the belt speed, completely eliminating or greatly reduc-ing spillage.

In addition to the impact experienced, excessive spillage also occurs, resulting in an increase in maintenance requirements.

Regardless of the direction or type of transfer, there are some design require-ments that require specific attention.

These include reducing dust, the elimination of blockages, reducing wear on chute liners and providing the correct discharge velocity, as well as minimising material degradation and conveyor belt wear.

Mark Baller of Weba Chute Systems maintains that there is a need to challenge con-ventional thinking around chute systems and transfer points. “The current trend seems to be that the company is called in to supply appro-priate solutions to recently installed chute systems that are not fully operational. This is a huge concern and needs to be addressed as a top priority.”

He asserts that many of the problems asso-ciated with transfer points can be eliminated during the design stage. “We therefore urge engineers to consult with Weba Chute Systems during this vital phase. The experience and expertise we have gained, during thousands of installations, is available to assist engineers both in the design of new transfer points and the redesign of existing systems that are becom-ing too expensive to operate.”

One of the most common problems associ-ated with conventional chute design is where the product drops, from any height, directly onto the belt. This basic design fault can cause major damage – and costs – as the impact of product falling directly onto the belt causes excessive wear and, in the worst case scenario, can even result in tearing of the belt.

In addition to the impact experienced, excessive spillage also occurs, resulting in an increase in maintenance requirements. This has a direct bearing on both productivity and costs, due to unnecessary downtime and component replacement.

Baller says the common practice of installing skirting and a skirting box as a remedy to con-trol spillage incurs an additional capital outlay

and is not guaranteed to alleviate the prob-lems associated with incorrect belt loading.

“In some instances, other apparatus has been used on con-veyor systems to avoid spillage caused by badly designed trans-fer points. However, these ‘Heath Robinson’ arrangements often cause tremendous damage to the belt because of the manner in which the skirting is fitted,” he points out.

Excessive spillage also causes material build up on idlers and can then cause major problems on a conveyor system if left unattended. In addi-tion, a chute that has been engineered to allow a direct drop poses a safety issue when liners need to be replaced. The maintenance crew will need ladders and harnesses to access the inside of the chute, which is not considered best prac-tice in the highly regulated mining sector.

Another factor that requires close atten-tion is the manner in which chute liners are installed. “Typically, chute liners are bolted or welded in place and the direct impact of mate-rial against these liners causes excessive wear. Additionally, liners can detach from the inner wall of the chute and fall through the chute, causing excessive belt damage, blockages further down the line and could even cause damage to the crusher,” Baller continues.

“Conveyor belting is one of the most costly items in any bulk materials handling opera-tion. Any operation achieving a lifecycle of less than three years life on conveyor belting needs to seriously review its transfer points, belt alignment, idler maintenance, pulley main-tenance and cleaners. Weba Chute Systems’ experienced team of engineers is available to undertake a full analysis of existing and new chute installations and design a solution that is geared around cost effectiveness and opera-tional efficiency,” Baller concludes.

www.pilotcrushtec.com

September 2014MODERN MINING47

BULK MATERIALS HANDLING

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A leading Botswana diamond producer has purchased Pilot Crushtec Modu-lar screening and materials handling

equipment twice in the past six months to in-crease output and operational efficiency.

According to Pilot Crushtec International Africa Sales Manager Wayne Warren, speed was of the essence in both instances and the Jet Park-based manufacturer’s ability to supply ex-stock had been a major selling point.

“In the first instance, our customer required a screen and conveyors to process tailings pre-viously regarded as a waste product from its main operation. The second took place during the maintenance shutdown of its main plant when it was decided to process selected sizes of material in order to continue the output of saleable product,” he says.

Warren adds that in both cases the out-come has been positive. The customer has also been impressed by the ease with which Pilot Modular products were installed and then re-configured with existing Pilot Crushtec plant as his requirements changed.

Modular equipment keeps production on track

The miner’s Pilot Modular fleet now includes a Pilot Modular grizzly feed hopper GFH560, a Pilot Modular DD2412 horizontal dewatering screen, a MC800 20 mm conveyor, six MC600 conveyors in various sizes and formats and two weightometers.

Pilot Crushtec’s equipment en route to the diamond producer in Botswana.

48MODERN MININGSeptember 2014

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INSTRUMENTATION & CONTROL

Electrical and instrumentation contractor, B&W Instrumenta-tion & Electrical (B&W), has

reported a phenomenal turnaround since it was acquired by engineered solutions provider ELB Engineering Services (ELB) in April 2014.

“Since the acquisition, which was only finalised on the 22 April this year, we have received orders to the value of R154 million and we expect further orders to the value of about R24 mil-lion in the near future,” says B&W CEO Brian Harley.

He continues: “Our ability to take on this work is a result of ELB’s com-mercial support, which has enabled B&W to close off old contracts, settle outstanding debt and consolidate its cash flow, which is now improving on

Smart Sensor from Booyco Electronics

Developed for local mining conditions to meet spe-cific requirements for gas

monitoring at fixed locations, the ESI Smart Sensor incorpo-rates unique design features that effectively address the shortcomings of conventional sensor instrumentation.

Available from Booyco Electronics, this unit fea-tures a localised display of sensor information and can

measure 15 different gases from a single controller typically

including oxygen (02), carbon dioxide (CO2), flammable gases such as methane (CH4) and combustible gases such as carbon monoxide (CO). The ESI Smart Sensor can also accommodate

other sensors with analogue outputs, such as air velocity sen-sors or smoke detectors.

A unique feature of the ESI Smart Sensor is its modular design that makes for ease of repair and calibration. If a sensor fails, only this sensor unit needs to be removed, eliminating the need to open the main enclosure to install a new sensor. Similarly, when the sensor calibration expires, the sensors can be replaced in situ with new pre-calibrated sensors.

Ingress protection on the ESI Smart Sensor exceeds IP56 and the instrument carries SANS IEC 60079 Part 0: 2005, SANS IEC 60079 Part 11: 2007 and IEC 60529 (IP code) approvals. Also certified as EXia T4 Intrinsically Safe, the unit’s dimensions are 265 x 150 x 60 mm and it weighs 1,8 kg.

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

“Phenomenal” turnaround at B&Wan ongoing basis. The bottom line is that B&W is once again in the black and operating profitably.”

Harley says the integration of B&W into the ELB group has been a very smooth process with the excellent co-operation between the various management teams and the strong culture fit between the two organisations underpin-ning B&W’s ability to continue operating without a ‘hiccup’ throughout the transition period.

ELB, which has a distinct pol-icy of maintaining strong brand

names in the market, has made it clear that B&W, which is one of the leading brands in the electrical and instrumen-tation industry in Southern Africa, will continue to operate as a stand-alone company.

A bonus for B&W is that Conductor Systems (CS), a leading supplier of electrical supply systems for moving machines, has been brought into the B&W fold and Harley says that both CS and earthing and lightning protection specialist Pontins – part of B&W since 2009 – represent an excellent growth opportunity for B&W.

“Like us, these two companies are leaders in their respective fields and the excellent product synergies that exist between all three companies will enable us to make the most of our

The stringent biodiversity management plan on B&W’s Ambatovy nickel project in Madagascar made it quite different – says the company – from most other contracts.

new-found muscle in being part of the ELB group,” says Harley.

He adds that the ability of CS and B&W to work together efficiently was amply demonstrated by the joint contribution they made to ELB’s suc-cessful repairs to recent fire damage at the Nestle Potchefstroom factory, which was brought back to operation in record time.

“Both CS and Pontins complement and supplement B&W’s core business and service offering and it is a dis-tinct advantage to our clients that we can now offer them a wider range of services throughout the entire project cycle,” says Harley.

He says that another major benefit of being part of the ELB group is the opportunity to participate in group projects, which will give B&W a base load for the future on a continuous basis. “B&W has identified, and will target, projects in the mining, solar, and oil and gas sectors in South Africa and Africa and, in addition, is looking to expand its services into the trans-mission and distribution sectors.

“Given the enormous advantage of being part of the ELB group and con-sidering the strong inflow of orders since the acquisition, not only does the current level of work and orders bode well for both the 2015 and 2016 financial years but our future identified pipeline of work is healthy across all sectors of our traditional business.”

September 2014MODERN MINING49

INSTRUMENTATION & CONTROL

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Rand Technical Services (RTS) is a Tshwane-based company spe-cialising in addressing specific

industrial challenges by identifying innovative solutions, often sourcing them internationally. The company, run by Chairman Ian Fraser, has been introducing cutting-edge technology to local industry since the early 1990s, not least of which are the company’s Neo Monitors laser gas monitors.

“Gas detection and analysis are critical to industrial processes: not only does the monitoring of gas levels address critical safety issues, but it can bring substantial cost savings through helping to optimise combustion pro-cesses. It can also promote a cleaner environment through focused emis-sions control,” says Fraser.

However, analysing gas levels may be subject to inaccuracies and limi-tations in environments of extreme temperatures or high dust levels. Neo Monitors laser gas monitors are claimed

Laser gas monitors available from RTSto bring new levels of capability and accuracy, providing a convenient answer to the problems associated with probe-based instrumentation.

“Gas analysis has historically been conducted through probes, which can be problematic in that gas streams tend to be dirty, hot and inaccessible. Normal probes clog up easily and are affected by high temperatures, affect-ing the accuracy of the readings. Probes can also experience a short life-span and require extensive maintenance,” Fraser explains. “Tunable diode laser technology offers an extremely viable alternative to probes-based instruments.”

The laser monitor is tuned to a spe-cific specially selected absorption line for a particular gas which enables the instrument to measure the level of the selected gas in the gas stream without cross-interference from other gases or contamination by dust particles, and is not negatively affected by high

temperatures. As a measuring device it is extremely stable, unlike other inst ru-ments which can provide inac-curate readings.

“These moni -tors remain accurate for a minimum of 12 months,” says Fraser. “They are a durable and therefore cost-effective means of measuring and analysing a large range of gases. Moreover, they are highly tolerant of opacity. Therefore, within a gas stream where there is at least a 10 % signal received they remain highly accurate. In terms of temperature, we have successfully used laser monitors in a platinum smelter with temperatures rising to 1 500 deg C.”

RTS’s range of laser monitors is manufactured by Neo Monitors, a division of Norwegian company Norsk-Elektro Optic (NEO).

A Neo Monitors laser gas monitor.

www.scaw.co.za

PRODUCT News

September 2014MODERN MINING51

Always on the lookout for new innovative ideas, Cobra Petro Projects, in conjunction with Ausroad, is introducing custom-made stemming trucks into the open-pit mining market.

Ausroad has reportedly been an indus-try leader in this field for some years now, building stemming trucks for both hire and sale. The practicalities and cost of import-ing such a truck are prohibitive. For this reason Cobra Petro Projects has, under licence to Ausroad, built the first locally produced stemming truck. This truck was on show at the recent Electra Mining show.

Lloyd Darby, MD of Cobra Petro Projects, explained how this innovative piece of machinery was finding favour in large opencut drill and blast operations. “The stemming truck’s function is to fill the blast holes on a mine site. The most significant operational benefit is the dra-matically increased speed and efficiency of the drill to blast cycle. Depending on the lube dimensions, a 16 m3 load can fill up to 60 holes and the truck can deliver 500 kg of aggregate in 15 seconds with ease.

“The aggregate is dispensed via an adjustable chute, found behind the driver’s door or via a 5 m boom-mounted conveyor which reaches far out beyond the vehicle. This means that stemming can be deliv-ered hard up against the rock faces. This is an easier and more efficient method and negates the necessity for other machinery.

“Less movement on the drill pattern leads to a decrease in occupational health and safety issues. The 3 400 litre on board water tank feeds a dust suppression sys-

Custom-made stemming trucks launched locally

tem which greatly reduces dust and heat exposure for ground staff.”

He added: “The aggregate flow control and rear boom manoeuvring is carried out via a joystick mounted in the cab or via a wireless remote control from outside the vehicle. This, together with an integrated control screen fitted into the dash, which will allow the operator to closely moni-tor the amount of aggregate delivered or remaining in the hopper, means that there is reduced handling of the stemming. This will also result in consistent loading per

Above: In conjunction with Ausroad, Cobra Petro Projects is introducing stemming trucks into the open-pit mining market.

Right: The aggregate is dispensed via an adjust-able chute or a 5 m boom-mounted conveyor which reaches far out beyond the vehicle.

hole, less wasted aggregate, and the more effective use of the emulsion.”

Cobra Petro Projects will provide stem-ming units from 10 m3 up to 16,5 m3, depending on the scale of the mining operation. Units are currently made to order. Cobra Petro Projects will, however, consider the hire of vehicles if the market requires this.Cobra Petro Projects, tel (+27 11) 613-3046

Support Roller System solves kiln problemSKF’s flexible Support Roller System was reportedly the ideal solution for a minerals processing customer based in Olifantsfontein who was experiencing con-stant kiln failure.

The main causes of the failures were poor running accuracy, as well as an inferior design that was incapable of withstanding the harsh environmental conditions. The standing time incurred due to these failures resulted in substantial cost repercussions and decreased production for the process-ing company.

The extreme heat generated inside a kiln oven or furnace must be maintained in

order to remove moisture from a substance. “This is one of the most stringent environ-ments,” says SKF South Africa’s Manshil Singh, who explains that the role of kiln roll-ers is to support the kiln and allow for slow rotation. “The bearings of the rollers must be capable of withstanding large static and dynamic loads and must be carefully pro-tected from kiln heat and dust ingress.”

The Support Roller System from SKF delivers high availability and low operat-ing costs. The complete solution includes: a robust roller design capable of withstand-ing harsh conditions; an improved material specification of the 1 m diameter support

roller to better manage the dynamic load-ing of the kiln; and on-site alignment and balancing to ensure maximum contact with the kiln tyre.

“We customised the sealing to prevent dust ingress and lubricant contamina-tion so that the support roller assembly could cope with such stringent conditions,” stresses Singh.

The system was seamlessly integrated into the customer’s infrastructure, keep-ing downtime to an absolute minimum. Premium SKF products were used to improve running accuracy and stringent quality control procedures were imple-mented to warrant reliability of assembly. SKF, tel (+27 11) 821-3602

PRODUCT News

52MODERN MININGSeptember 2014

Caterpillar’s new Cat 950 GC wheel loader – available from Caterpillar dealer Barloworld Equipment – has been launched alongside the existing and well proven Cat 950H model to provide customers with a cost effective alternative within the 5-ton pay-load segment.

The key difference between the two models is in their working applications: the Cat 950H is intended as a high pro-

New Cat wheel loader designed for support tasksduction unit for heavy duty roles, whilst the Cat 950 GC has been purpose-built for support tasks working mainly with loose materials.

Manufactured at Caterpillar’s Qingzhou facility in China, the assembly of the first Cat 950 GC units commenced from the fourth quarter of 2013 for distribution to worldwide markets.

“Rather than offering the ‘all in one’ solution characteristic of the Cat 950H, Caterpillar has fielded the Cat 950 GC as a niche wheel loader intended to pass on lower owning and operating savings. This is especially the case where the heavy duty roles for which the Cat 950H has been developed are not required. Either way, both models deliver best in class fuel effi-ciency and excel in their respective roles, with a comparable operating weight of around 18,6 tonnes,” explains Barloworld Equipment Product and Application Specialist Brandon Stonefield.

The Cat 950 GC features Caterpillar’s proven Z-bar loader linkage, providing aggressive digging abilities and high breakout forces.

Cable available for underwater applicationsSubmersible pumps require electric cable that is suitable for use in underwater applications. The cable must be flexible, robust and able to prevent any ingress of water or contaminants entering the cable via the sheath.

Aberdare Cables, a Powertech company, manufactures submersible pump cable that provides power supply to mobile and portable submersible pumps such as those used in quarries, dewatering applications and boreholes.

The cable comprises high conductiv-ity bunched flexible copper conductors to SANS 1411 Part 1. The cores are insulated and bedded with flexible grade waterproof PVC to SANS 1411 Part 2. Final protection is

provided by a flexible PVC outer sheath.Available in sizes from 1,5 x 3 mm2 to

16 x 4 mm2, the cable is supplied in three-core and four-core options. Cable core configurations are easily determined as Aberdare uses green as a sheath colour on four-core cables and blue for three-core cables. Meeting SANS 1574 requirements, the cable has a -10 to 70°C operating tem-perature range, a 600/1 000 V rating and is available in 500 m wooden drums.

It is recommended that for special applications of submersible pumps, the manufacturer is consulted to ensure correct application. Aberdare Cables, tel (+27 11) 396-8000

Powered by a Cat C7.1 engine that meets Tier 3 emission standards, the Cat 950 GC is well-suited for a wide range of tasks. These include stockpiling, truck loading, material handling, hopper charg-ing and load-and-carry work in quarries, sand and gravel pits, coal operations, stor-age yards, concrete and asphalt plants. On construction projects it can be used for job site preparation, back-filling, pipe han-dling, plus general cleanup.

In contrast, the Cat 950H is designed to perform tasks that include hard bank load-ing as the primary application – rock face loading; waste handling; forestry; demoli-tion and recycling.

Like the Cat 950H, the Cat 950 GC fea-tures Caterpillar’s proven Z-bar loader linkage, providing aggressive digging abili-ties and high breakout forces. The Cat 962H wheel loader model linkage geometry and design has been utilised as standard on the Cat 950 GC to provide best in class bucket pin height and dump clearance.

Load sensing hydraulics produce flow and pressure for the implement system upon demand and only in amounts neces-sary to perform the needed work functions.

As an option, machine owners can fit the Cat Fusion quick coupler system, enabling the rapid interchange of a diverse range of Cat work tools.

On the go, the Cat 950 GC’s electroni-cally controlled automatic powershift countershaft transmission features shift protection and is equipped with a split flow oil system for added efficiency, dura-bility and smoother gear changes. This contributes significantly to fast cycle times and extended component life.Barloworld Equipment, tel 0800 21 22 48

September 2014MODERN MINING53

PRODUCT News

Manitou Southern Africa launched three new flameproof mining machines and introduced the world’s largest telehandler – the MHT 14350S – to the mining industry at Electra Mining Africa.

The Manitou MHT 14350S – which has a maximum lift capacity of 40 tons – fea-tures advanced usability improvements and has a 7,2 litre Mercedes-Benz engine. It caters for the growing heavy-industrial market and, in South Africa specifically, for the handling of conveyor belt reels, tyre assemblies, wheel motors and the like in the mining sector.

The three new flameproof mining machines which were launched are the Manitou scaler, a roof bolter and the ManiTrax tow tractor.

The scaler enables operators to scale hard and soft rock from secure areas on its 7 m, 180° rotational turret, either from within its fully-enclosed cab, or from up

Johannesburg-based JLG and Magni aerial work platform and telehandler distributor Eazi Sales & Service has sold a JLG 800-AJ 26-m working height rough terrain articu-lating boom lift and a JLG 260-MRT 10-m working height rough terrain scissor lift to Barloworld Namibia. They are being used as support equipment in assembling and maintaining 14 units of some of the world’s largest mining machinery. Some of the machines weigh in excess of half a million tonnes.

Caterpillar equipment being assembled includes three hydraulic 6060 excavators, two MD 6640 electric drills, three electric rope shovels and six MD 6290 mechani-cal drills. They form part of the mining fleet that Swakop Uranium will be using at the new Husab mine near Swakopmund in Namibia. The mine is currently under construction.

Barloworld Namibia had considered similar machines from other suppliers, according to MD John Hosking. However, none of them was adequate to effectively assist in this type of machine assembly. Safety and efficiency, local representation and the impact that JLG equipment has on Barloworld’s ability to assemble towering mining equipment influenced Barloworld

JLG units help assemble Cat machines

The JLG 800-AJ rough terrain articulating boom lift in action as personnel make use of its 26-m working height in assembling one of Caterpillar’s electric rope shovels.

Namibia’s decision to utilise Eazi Sales & Service. “Eazi Sales & Service has local rep-resentation,” Hosking points out. “Support is close by and onsite training for our per-sonnel is convenient and hassle-free.”

“The fact that JLG was selected for this project,” adds Eazi Sales & Service Managing Director Larry Smith, “underscores previous validations that our equipment is among the safest and most reliable.”

Commissioning of Swakop Uranium’s newly purchased equipment is expected to be complete by December 2014. Larry Smith, Eazi Sales & Service, tel 086-100-5540

to 20 m away via remote control for maxi-mum safety. Traditionally a telehandler attachment, the scaler can be fitted with several attachment variations itself, and has secondary functions such as pipe and cylinder fitment and mesh erection.

The roof bolter is an automated drill and bolt rig that offers manoeuvrability and performance in confined soft and hard rock hanging walls as low as 1,8 m. The unit, a permanent fixture to the Manitou MT-X 742 telescopic handler, consists of a single rotating carousel head, which carries six roof bolts.

The ManiTrax tow tractor is a utility vehicle used for hauling, towing and trans-porting purposes in mining applications. Manitou has designed this tow tractor with full four-wheel crab steering functionality for maximum manoeuvrability – ideal for underground, confined spaces.Manitou Southern Africa, tel (+27 11) 975-7770

World’s largest telehandler introduced

PRODUCT News

54MODERN MININGSeptember 2014

High Power Equipment Africa – HPE Africa – distributes a wide range of earthmoving and mining equipment, which includes mobile crushing and screening units, as well as hydraulic hammers and drills.

“MB crusher buckets, McCloskey mobile crushing and screening plants and Soosan hydraulic hammers and drills, available exclusively in Southern Africa from HPE Africa, ensure efficient performance and extended service life in harsh operat-ing conditions,” says Dave Davel, Product Specialist, HPE Africa. “This robust crush-ing and screening equipment is suitable for small, medium and large scale projects in mining, quarrying, construction, demoli-tion, recycling and agriculture.”

MB jaw action crusher buckets are designed for on-site crushing of inert materials and unlike other crusher buck-ets on the market, this range is also able to process and crush material containing rebar steel. The buckets are easily attached to excavators, from 20 t to 36 t, using spe-

cially designed mechanical or hydraulic universal quick couplers.

An important unit in the McCloskey range is the C38R recirculating cone crusher, with key features that include a metal detector, an anti-spin system, inte-grated hopper and fully hydraulic push button and relief system, with load and material level monitoring.

These Telsmith 38SBS cone crush-ers, which are powered by Cat C9 Tier 3 engines, accept a material feed size up to 200 mm and offer a throughput tonnage up to 220 t/h, depending on the closed side setting. The single deck recirculation screen on the same chassis allows over-size material to be returned to the crusher feeder which prevents material oversize wastage and significantly reduces opera-tional costs – there is no double handling and all tasks are handled on one chassis.

McCloskey heavy duty track-mounted recirculating cone crushers have impor-tant safety features that include a start

Crushing and screening solutions from HPE Africa

Key features of McCloskey C38R recirculating cone crushers include a metal detector, an anti-spin system, inte-grated hopper and fully hydraulic push button and relief system, with load and material level monitoring.

siren, emergency stops and engine shut-down systems. The screen attachment to the chassis has a bolt-on design for quick screen media change.

The units have four jacking legs on each corner to stabilise the crusher in uneven terrain. The tracks are bolt on, rather than weld on. The advantage is that – in the event of a track problem – the crusher can simply be jacked up and the entire track, including final drive, removed and trans-ported to the workshop for repair, without any disruption to crushing operations.

A key feature of the McCloskey mobile range is the over-ride system which is acti-vated in the event of a sensor failure.

HPE Africa’s range of Soosan hydraulic breakers includes the recently launched SU+ series, which has been designed with a higher power to weight ratio and increased impact frequency for greater production efficiency. The newly devel-oped bounce controlled percussion system minimises recoils during hammering work to reduce damage at the hammer and carrier, also improving operator comfort. A thermal stress analysis system controls heat generation and protects the breaker from excessive heat.

Applications for these hydraulic breakers include primary and secondary breaking in quarries, site preparation and foundation work, road construction, trenching, tunnelling and bench levelling, as well as general construction works.

This range is compatible with TLB digger loaders, as well as 20 to 36 ton excavators.

HPE Africa, Capital Equipment Group (CEG), Invicta Holdings Limited, tel (+27 11) 397-4670

RTS displays spin filter technology at Electra MiningTshwane-based Rand Technical Services (RTS) showcased its spin filter technology at Electra Mining 2014, held in Johannesburg earlier this month (September). Although the technology has been in operation around the world for the past 20 to 30 years, uptake has been comparatively slow in South Africa, according to Ian Fraser, MD of RTS.

The company has been at the forefront of introducing spin filter technology to the local market, engineering it to suit heavy industrial applications, with a strong focus on mining.

“It is gratifying to see that spin filters are

becoming increasingly commonplace on a number of mines in this country, but they also have application in a number of other areas of industries where a clean, continu-ously dust-free environment is required,” Fraser says. These include transformer rooms, Motor Control Centre rooms, labo-ratories and the like.

Fraser explains how the technology works: “Spin filter units are a high-efficiency application of cyclone technology. Air to be separated is blown through a module that consists of a series of small vortexes. The air flow is induced to spin by fixed vanes at the

entry to the vortexes, and centrifugal force then drives the dirt particles to the outside of the vortex.

“Spin filters are designed for the opti-mum vortex size of 35 mm and will remove 98 % of dust particles 15 micron and larger (15 micron is about one sixth of the diam-eter of the average human hair). The dust is then collected and disposed of, instead of polluting the environment.”

The technology, therefore, has impor-tant benefits when it comes to ensuring a cleaner environment. It also offers long-term cost-saving benefits because it requires little or no maintenance.RTS, tel (+27 12) 993-9620

PRODUCT News

September 2014MODERN MINING55

Applying continuous ion filtration (CIFTM) in the mining industry will bring signifi-cant benefits – and Multotec is poised to do this following its recent announcement that it will be launching water process-ing solutions in Africa in partnership with Australian company CleanTeQ.

Multotec will be the African repre-sentative for the CleanTeQ range of ionic filtration systems, and a phased rollout of the systems is planned during 2014.

“This is a significant coup for Multotec and the team is excited about the pros-pects for the treatment of mine wastewater and acid mine drainage (AMD). By applying the CIF technology to the mining industry, we will be able to contribute to the drive to preserve our valuable water resources,” says CJ Liebenberg, Environmental Process Engineer at Multotec.

While CIF is based on ion exchange (IX), a technology that has been on the market for over 50 years, it also resembles continuous sand filtration with the salient differences being that CIF uses charged IX

resin beads instead of sand as its filtration medium, and it ‘filters’ dissolved solids out of solution in addition to suspended solids.

Each CIF module comprises a series of columns each designed for a specific function – ionic filtration, resin washing (pre-elution wash), resin regeneration and resin rinsing (post-elution wash). Resin moves as a packed bed in the columns with resin continuously being transferred from the bottom of each stage to the next. Counter-current operation ensures opti-mum mass transfer and continual high contaminant removal.

Liebenberg explains that the CIF tech-nology complements the other products and services in Multotec’s portfolio. “Multotec’s core business is the supply of products and services to the mining and mineral beneficiation industries including solid/liquid separation equipment such as centrifuges and filter presses. Our aim is to assist in the alleviation of water short-age issues and to encourage sustainable development in South Africa. Mining is

Multotec to supply continuous ion filtration systems

A CleanTeQ operated CIF plant treating 0,6 ml/day of borehole water containing approximately 8 000 mg/l TDS, 100 mg/l calcium, 400 mg/l magnesium and 1000 mg/l bicarbonate. CIF was used to remove calcium, barium, strontium and bicarbonate prior to employing MMF/RO desali-nation. The use of CIF as a pre-treatment for RO increased the system’s water recovery by 5 % and the reliability of the MMF/RO.

often regarded as being a non-sustainable enterprise from an environmental per-spective and we would therefore like to become part of the solution, rather than the perceived problem.”Bernadette Wilson, Multotec Group, tel (+27 11) 923-6193

PRODUCT News

Buying a heavy mining-class dozer is a con-siderable capital investment, particularly when the machine is required to earn an income in the plant hire business. Having bought several of these dozers in the past ten years since establishing Burma Plant Hire, Theuns Burger is all too aware of the requirements and which machines are able to run most profitably.

When it comes to dozers, Burger’s first choice is Komatsu. He extends the same buying preference to other new equip-ment in his 400-strong fleet.

The company’s latest purchase of a Komatsu D375-6 dozer to service the

mining industry underscores its trust in Komatsu products.

“For me, this business is all about pas-sion. I was trained and grew up surrounded by earthmoving machines and still love them – and still have a passion for them. I know the details of each machine in my fleet and make a point of keeping track of every detail of its performance and avail-ability throughout its lifespan,” says Burger.

“Similarly, I get to know each operator and try to understand them and know what makes them perform and stay moti-vated. By remaining on top of things, I am best able to make the right decisions and service my own clients with the machines they need when they need them. I also try to instil this same passion in my staff and truly believe I have done so successfully judging by our track record.”

The company had bought most of its machines from another manufacturer until Jimmy Smith and Francois Griessel of Komatsu in Cape Town convinced Burger to do otherwise. Although initially reluc-tant to venture out of his comfort zone, he Burma Plant Hire’s Komatsu D375-6 dozer.

Burma Plant Hire opts for Komatsu machinesdid eventually opt to buy a Komatsu PC200 excavator and was pleased with its overall performance – with the result that more machines were subsequently purchased.

“As we expand beyond our core busi-ness of supplying equipment to the road building and construction industry, we have also come to rely on Komatsu to pro-vide us with the right machines for new operations in mining, load and haul and related projects. Our business has also expanded its footprint from the Western Cape to having full branches with work-shops and other necessary facilities in Port Elizabeth, Gauteng, Kathu, Postmasburg and Steelpoort and we are setting up branches in KwaZulu-Natal and Namibia.

“We don’t buy machines to park them! In terms of productivity and utilisation, the more uptime we have, the better for us. Komatsu machines give us what we need and we have found that after about 8 000 hours the results speak for themselves and the Komatsu’s are our very top performers,” says Burger. Komatsu Southern Africa, tel (+27 11) 923-1000

September 2014MODERN MINING57

PRODUCT News

Software developed by Sandvik to optimise drilling and blastingEfficient tunnelling and mining of underground resources is being aided by the introduction of specially developed mining software from Sandvik Mining that optimises drilling and radically enhances blasting effectiveness.

After extensive evaluation on mines globally, the software has finally been introduced to mines across the sub-Saharan region wherever tun-nelling and blasting operations are taking place. It allows users to track tunnel development in real time and gives them the opportunity to assess blasting outcomes before they take place.

Intelligent Sandvik Underground Rock Excavation (iSure) is effectively an advanced tunnelling project management suite with tools that pro-vide guidelines for different stages of the drilling and blasting process. These are designed to enable miners to achieve optimal speed and effi-ciency, while taking loading and hauling requirements into account.

According to Saltiel Pule, Sandvik’s Business Line Manager for Underground Drills, the software is unique. Not only does it guarantee smooth tunnelling work but it can specifically guide users on the differ-ent stages of the drilling and blasting pattern process to achieve best possible results.

Furthermore, it provides hole-burden calculus and enhances hole location accuracy, which, in turn, reduces the need for scaling and ensures better blasting and pull-out. This also allows better rock load ability and smoother collaring when the next round of drilling and blast-ing begins.

“In a nutshell, iSure combines tunnel-line, theoretical profile design and drill-plan design, as well as data collection analysis. Rather than relying on less accurate traditional approaches, it provides users with tunnelling patterns to be configured at the end of the round (when the success of blasts is critical). iSure also offers a project tree that combines all tunnel plans in one project and can include either one tunnel plan or several different plans,” says Pule.

Users have access to four modules which include iSure Tunnel for drill and blast design, drilling pattern design, long hole pattern, tunnel line and project files. iSure Bolting provides designs for up to five bolting fans, hole placement and direction, tools for hole generation and fan management, while iSure Report provides the necessary drilling man-agement and process developments required on site. iSure Analysis is used more holistically for measures of drilling data collection and analy-sis of rock structures and characteristics.

“Currently, we have introduced iSure into our 400-series mining jum-bos including the DD421-60C drill rig, which provides operators with data relating to their own tunnel developments,” says Pule.Sandvik Mining, tel (+27 11) 929-5400

Projected drilling accuracy using Sandvik Mining’s iSure technology.

PRODUCT News

58MODERN MININGSeptember 2014

IS barriers are tailored for Southern African miningBooyco Electronics supplies a range of IS (intrinsic safety) barriers tailored to the spe-cific needs of the Southern African mining and petro-chemical industries. These barriers are suitable for use in all hazardous areas and are compact, easy to use and robust enough for both surface and underground environ-ments. A major advantage is that they are single-device barriers, with each unit serving as an isolation barrier on a communication bus between a non-hazardous and hazard-ous area in a mine or plant environment.

The application of alternative battery technology has resulted in the develop-ment of an IS uninterruptible power supply (UPS), which offers reliable performance under the harshest operating conditions. The Booyco Electronics IS-UPS is locally manufactured under stringent quality man-agement systems and meets all statutory

regulations pertaining to IS equipment. This innovative technology provides a

direct current output of 12 V or 24 V or a combination of both for extended peri-ods of time and is suitable for a number of critical applications, including maintaining communications systems and fire detection systems. To cater for individual application requirements, the units can be supplied in multiple outputs.

Combining the IS battery with the IS-UPS eliminates the dangers associated with a conventional UPS, making it possible to use a far lighter, and more cost effective, explosion proof enclosure.

Also part of the IS barrier range is Booyco Electronics’ active high power, 2 A at 12 V IS Power Supply Unit (PSU), suitable for providing items in hazardous areas with DC IS power. The IS-PSU includes overload

protection and isolates the load from the power supply when an overload occurs.

The latest addition to the IS range is one of South Africa’s first IS tablets. IECex Ex ia Group 1-certified for use underground in fiery mines, this sturdy full sized tablet car-ries an IP54 rating for ingress of dust and water and is drop resistant from the stan-dard height of one metre.

Designed for local underground min-ing conditions, the unit can be connected with a Booyco Electronics-supplied, USB-powered Ethernet barrier to provide galvanic isolation. The Booyco Electronics IS tablet has a battery life of up to eight hours and runs off any Windows embedded oper-ating system. It is able to interface with the mine’s Wi-Fi network and can be utilised as a programming tool and to draw data from other electronic equipment in the Booyco Electronics range.Anton Lourens, Booyco Electronics, tel 0861 BOOYCO (266926)

MBE Minerals reports that it provides a broad range of capital equipment for the iron ore beneficiation processes and is able to access over 150 years of experi-ence gained in the tough and demanding global mining industry, with more than 40 of those in Africa, to determine best-fit solutions.

According to the company, the iron ore industry is increasingly recognising the high efficiencies, significant economic benefits, improved product quality and machine availability, as well as the higher throughput rates, that are achievable with MBE Minerals’ BATAC® jigs.

“Stratification by means of jigging is one of the oldest separation methods in the history of mineral and coal beneficia-tion,” says Johannes Kottmann, MD of MBE

MBE provides iron ore beneficiation solutionsMinerals. “In the early days of beneficiation, separation was achieved either by moving the entire jigging bed screen (side pulsed BAUM jig), limited in operating width to 2 m and hence throughput capacity, or through water pulsation generated in an air chamber beside the jigging bed. In the 1960s, to overcome the counter-productive limitations of these historical technologies, MBE introduced the under-bed pulsed high throughput capacity Batac® jigging technology to the market.

“BATAC® jig technology has excellent separation accuracy, is relatively small in footprint and has a comparatively low cap-ital cost,” Kottmann says. “Every benefit the technology offers has been field-proven through extensive and diverse test work.”

MBE’s robust Jones® Wet High Intensity Magnetic Separator (WHIMS) is characterised by a high throughput capa-bility, coupled with simple maintenance and lower energy consumption. The com-pact Jones® unit allows installation in small buildings and is said to be ideally suited to treating feebly magnetic minerals with a particle range from 20 µm up to 1 mm.

PERMOS MIMS is a cost effective, medium-intensity magnetic drum separa-tor which allows wet and dry separation of high grade coarse and fine ferromagnetic and paramagnetic ores with a medium susceptibility, at high throughput rates, with minimal energy consumption.

MBE’s Jones® Wet High Intensity Magnetic Separator (WHIMS) offers a high throughput capability.

MBE Minerals’ Pneuflot® technology is said to exhibit a number of advan-tages over conventional technology. “The flotation cell improves product quality, recovery and efficiencies, as well as delivering lower capex and opex, and significantly lowering wear costs. The implementation of Pneuflot® has also resulted in substantial savings in energy consumption, space and manpower requirements,” says Kottmann.

Available in sizes ranging in diameter from 800 mm to 6 m, the Pneuflot® systems have been successfully installed in a num-ber of industrial applications. Slurry feed rates of 10 to 1 400 m3/h can be achieved in a single cell, depending on cell diameter.

The company’s vibrating screens have a well-established track record in the African mining industry, with products available for sizing, scalping, dewatering and media recovery. The screens feature an innovative side plate mounted drive, making them lighter than those utilising vibrator motors.

The company’s range of vibrating feeders, designed in Germany and manu-factured locally, features feed capacities of 100 up to 3 000 t/h. Units are suitable for all applications where controllable discharge of bulk materials is required. Replaceable bolt-on wear liners are fitted to the feeder troughs to prolong feeder life. MBE Minerals, tel (+27 11) 397-4660

PRODUCT News

September 2014MODERN MINING59

ACTOM Mechanical Equipment has com-pleted two contracts, totalling over R50 million in value, for the extension of the main ventilation fan system at Anglo American Platinum’s Bathopele mine near Rustenburg in North West Province.

The contracts, awarded by Anglo American Platinum’s project management and design consultants, RSV, were for the mine’s Expansion Phase 5 being developed to gain access to additional ore reserves, aimed at increasing output to 300 kt/month by 2014.

ACTOM Mechanical Equipment won the first contract for the expansion of the Central Shaft mining area in early 2012 against stiff competition from other suppliers.

The turnkey contract was completed in mid-2013. It involved the design, manufac-ture, supply and installation of a 165 m3/s capacity centrifugal surface ventilation fan equipped with a high-efficiency Fläkt Woods design backward curved aerofoil

section impeller to extract air out of a 3,1 m diameter, 60 m deep raise-bore shaft at a pressure of 3 500 Pa.

“The contract also required us to con-duct a computerised fluid dynamics (CFD) analysis to prove the efficiency of the fan design,” said Mike van Oerle, ACTOM Mechanical Equipment’s Product Manager, Mining Fans.

The scope of the contract included sup-ply and installation of medium and low voltage electrical switchgear and controls, as well as the civils and building of an access road to the site. Local contractors in the vicinity were hired to execute the civils and roadworks portions of the contract.

The larger second contract for expan-sion of the West Shaft was awarded at the end of 2012 and was completed in May this year. This comprised a bifurcation fan of identical design and capacity as the first to be installed in a 4,5 m diameter, 62 m deep raise-bore shaft to extract air at a pressure of 3 500 Pa.

Main vent fan contracts for Bathopele completed

The bifurcated fan installation at Bathopele’s West Shaft.

“This was also a full turnkey contract with the same scope as the first, except that no road was required to be built in this instance,” Van Oerle commented.

All the fans are powered by 800 kW cus-tomised UNIBOX motors manufactured by ACTOM Mechanical Equipment’s sis-ter company ACTOM Electrical Machines’ Large Motors business unit.Craig Johnston, ACTOM Mechanical Equipment,

tel (+27 11) 878-3029

PRODUCT News

60MODERN MININGSeptember 2014

Index to advertisersADT Tyco IBCAfrimat 59ALCO-Safe 11B&W Instrumentation & Electrical 49Barloworld Power 18Bell Equipment Co 7BME OBCBooyco Electronics 57Cobra Petro Projects 2DRA Mineral Projects 9

Flexicon Africa 13FLSmidth 41Joy Global Africa 15Komatsu 53Hansen + Genwest OFCM & J Engineering 47MDM Engineering IFCMining Indaba 22MMD Mineral Sizing Africa 36Novatek 17

PANalytical 55Pilot Crushtec 46Sanitech 52Scaw Metals Group 50Servest Multi Service Group Botswana 28SEW Eurodrive 44Wearcheck 56Weir Minerals Africa 32WorleyParsons 19

Integrated Pump Technology (IPT) has been appointed as the exclusive distributor in Southern Africa for Grindex, the world’s third largest submersible pump manufac-turer. Located in Bartlett, Boksburg, IPT is a pump-focused business. It will assume responsibility for the development of the Grindex business in a number of high potential African countries.

“Integrated Pump Technology already has the expertise, infrastructure and capa-bilities to service long-standing Grindex

customers while growing its pump instal-lation base further,” says Graham Russell, IPT’s Executive Chairman.

Grindex has had a presence in South Africa since the late 1980s, most recently through Voith Turbo. “Our first job since acquiring the agency is to assure the market that it is business as usual. We guarantee relationship, product, service and price structure continuity. Integrated Pump Technology is delighted to continue the long association with Grindex in South Africa, where it is a household name, and we look forward to the challenge of grow-ing the brand in Africa,” Russell says.

Located in a new industrial business park close to OR Tambo International Airport, IPT boasts a newly built 1 200 m² warehouse and offices.

“We have an established distribution network of 16 strategically located and specialised pump companies and key account managers whose proximity to our end users provides a fast, personal

service,” says Russell. The warehouse sup-ports the distribution structure in terms of sales, repairs and rentals to Botswana, Namibia, Zambia, the DRC, Mozambique and Zimbabwe.

IPT will use its new facility to develop its rental model, a new development for Grindex in this market. “We see the rental business as a big opportunity and are building a significant rental stockholding to service this sector,” Russell states.

“The South African and sub-Saharan African markets were the largest export markets for Grindex in 2011 and 2012 and the second largest in 2013. This year is already looking exceptionally good for us, driven largely by our exports to Zambia and the DRC. There is a full service and test facility in Zambia. We are hoping to regain our number one position this year and look on track to do so,” Russell continues.

Recent flagship contracts include the supply of 25 highly wear resistant Bravo 700 submersible slurry pumps to the DRC and a further 12 submersible Mega N pumps to Zambia. In South Africa, Grindex has enjoyed a number of successful demonstration test trials in pond dewatering applications.

A feature of the Grindex dewatering products is the capability of the sub-18 kW range to run dry. This is due to a unique air valve integrated into the pump which allows the impeller to pass air instead of water past the motor in a dry run condi-tion. The patented smart motor protector ensures thermal overload, phase loss and phase rotation protection.

The dewatering and sludge pumps are also available in cast 316 stainless steel, with a capacity of handling pH values between 2 and 13, which means they are well suited to process applications.

Klint Bawden, Integrated Pump Technology, tel (+27 76) 840-6527

IPT appointed as Grindex distributor

Grindex drainage pumps are heavy duty industrial strength, yet still lightweight and highly portable.

Mine site accommodation service offered by G4SG4S, a leading international global inte-grated security company, has announced that it will be able to build, run, manage and maintain accommodation villages for employees working in remote sites, sup-porting its energy, mining and construction customers throughout Africa.

G4S’s Remote Site Facilities Services (RSFS) will be supported by a dedicated team of experts who will design and build camps, and provide a wide range of facilities management services including catering, cleaning, maintenance, medical services, recreational activities, and waste management.

The intention is to create a ‘home-away-from-home’ for people working in isolated, high risk locations, who often spend long periods of time away from their own homes. The company aims to create these villages to ensure the comfort of its customers’ working and living environments.

As part of the new service line, G4S will be able to develop camps ranging in size from small 10-person seismic or drilling exploration camps right the way through to camps serving large construction proj-ects of 15 000 employees or more. Albert Erasmus, G4S South Africa, tel (+27 10) 001-4500, e-mail: albert.erasmus@za.g4s.com

www.tycosecurity.co.za

www.bme.co.za