MDM JAN FEB 2015

MMIINNIINNGG DDEEVVEELLOOPPMMEENNTTSSJanuary/February 2015 Issue MAGAZINE



Becker Mining South Africa - IGBT tractionbattery chargers Becker Mining South Africa's cooled traction battery chargers. correct charging. Other cell recently launched IGBT mine configurations and various Amp/hour traction battery chargers have “These IGBT battery chargers are ratings (100 A/h to 1 000 A/h) can be lightweight air cooled units, which are programmed and stored through the user been designed to charge controlled by an intelligent micro interface, with no additional changes to underground traction batteries processor circuit that acts as the main the battery charger itself.in the shortest possible time, at control computer, responsible for the logging, charge functions and controls. For the efficient management of mine the lowest possible traction batteries, Becker Mining's robust temperature, to ensure “Becker Mining's new chargers utilise chargers have an integrated power line optimum battery performance. Delta Volts/Delta Time (DV/DT) for the communication (PLC) identification precise detection of a battery's gassing method, which automatically logs theBecker-igbt-traction-battery- stage so the charger can terminate the serial number, as well as the chargechargers…one second rate charge more rapidly. This history related to that specific battery.Becker Mining South Africa's recently technology, which prevents over-launched IGBT mine traction battery charging often associated with Becker-igbt-traction-battery-chargers have been designed to charge conventional battery chargers, ensures chargers…twounderground traction batteries in the reduced charging times and lower power The user interface is a full colour displayshortest possible time, at the lowest consumption. By reducing the charge which provides relevant information,possible temperature, to ensure optimum current once DV/DT is reached, batteries including voltage, current, state ofbattery performance. are charged at a significantly lower charge, temperature of stack, capacity temperature.” charged, duration of charge, errors, time“The most common causes of battery and date.failure and reduced service life are With an improved power factor of 0,8associated with incorrect charging and a maximum input current which has Becker Mining's IGBT traction batterytechniques,” says Andrew Trentelman, been reduced from 42 A to 32 A, these chargers are equipped with Wi-Fi tosenior general manager: electronics, energy efficient battery chargers offer facilitate future downloading of data,Becker Mining South Africa. “Becker power savings up to 10 KVA during errors and the charge history of eachMining's new IGBT mine traction battery maximum output current. battery, or for viewing or analysis on thechargers, which utilise insulated-gate surface.bipolar transistor (IGBT) technology for The auto cell detection system enablesquick on and off switching, are more IGBT chargers to execute a short test Becker Mining South Africa offers aefficient and cost effective than charge on every battery to the determine technical advisory and support service toconventional transductor controlled, oil- the number of cells connected to ensure mines throughout Southern Africa. 1



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Keestrack - SACrushing & Screening Equipment Our Experience Your key to Success 4

MOTION DETECTION IN MININGMotion detection in mining is the process of when an ample variation is detected, thediscovering motions in mining surfaces and video frames that contain the motion areslopes and thereby providing alerts for then recorded to the computer's hard drive,possible dangers. This process is made and thereafter the alarm is set in motion.effective via the application of digital Alternatively, through an Internetelectronic cameras in conjunction with connection, the detective system can becomputer technologies that are characterized configured to visualize the scene therebywith computer software. With the computer, dialing a designated telephone number in thevideos and data coordinated by the digital event a trigger occurs.cameras are safely saved. The saved videos Video motion detection is vital as it detectsand data act as parameters towards the most minor changes within a miningproviding the actual signals for warning surface; whether a rock fall or even wallagainst the possible mining danger to occur. hazardous cracking on the mines. VideoThe motion analysis software aids in cameras need only to be steady to becalculation of parameters like distance, effective and free from causing falseacceleration, velocity as well as angles of triggers. Recorded video images do not onlydeformation. The same parameters can as aid in warning workers against dangerouswell be used to design safety motion working environs but they do also enable theequipment that performs accordingly. mining investigators to reconstruct a rockAt times, detection in mining may fail due to fall as well as establish the unstable groundsfactors such as masking, which interferes of mining surface.with the camera’s viewing. Other problemsfacing detection in mining include false 5alarms caused by aspects of weatherconditions such as wind, snow and the rains.Weather conditions may be uncontrollable,but modifications to harden the mast as wellas stabilizing the mount of the camera couldbe of significant help.Effective motion detection in mining is alsoachievable via establishing the use ofmultiple video cameras within the miningscene. Multiple video cameras are capableof monitoring several areas simultaneouslyusing diverse resolution, mask setting andzoom. In addition, the system can beimplemented for big range of monitoringtasks.Detection in mining also covers detection ofrock falls, which are a tragedy if notdetected in advance. The system is set torecord video frames and when the motion ofrocks is detected, an audio alarm is triggeredimmediately. Algorithm, which monitors theintensity value of every pixel in the sight,enables detection to be accomplished and



DRILLING AND BLASTING Blasting has historically been a risky operation, but AEL Mining Services is intent on paving the way tozero harm and finding the 'missing link' to deliver optimal blasting solutions. This mammoth task requires the collective efforts of the industry to be truly successful,AEL Mining Services is calling on the industry chemicals only become active when mixed.” mixer and gassing solution is controlled onto collaborate on efforts to improve workplace AEL's underground bulk system (UBS) comprises surface and the product only becomes an three components, emulsions which can be explosive once it is mixed through the lance at safety and risk exposure in the evolving bagged or delivered to the working place through the stope face underground. mining environment. a pipe from surface, a sensitising agent and a pumping mechanism. While widely accepted as Ever improving in Africa and beyondZero harm is possible, as AEL proved at the industry standard for underground mining, Improving the delivery of emulsions Kumba Iron Ore's Sishen mine in early it is continuously evolving within the walls of AEL's underground is an ongoing concern for AEL, 2014, where a record blast of 311 mm holes research and development department. as is “how wewith a total of 70 8446 t moved was achieved with get even deeper,” says Tose, but thean excellent safety record of zero injuries and New and improved emulsion formulations, company's vision for ongoing improvementzero incidents. pumping systems and value-add services targeted does not end with its products. to this industry are constantly being realised asSubsequently, the blasting section managed to AEL continues in its efforts to improve its offering. AEL is not a product peddler but rather aset a new record for total tons blasted in a week value-adding service provider that strives to(7.4 Mt) without an incident. Enhancing safety and reducing risk is one of the optimise its customers' mining operations. “For major drivers behind AEL Mining Services, and us, it is aboutAt Sishen, AEL demonstrated its prime, load, tie the company is constantly striving towards being connected to a certain service, and weand/or shoot (PLTS) service, which addresses creating innovative technological advancements in are interested in developing and matchingthe requirements of customers that face resource the mining industry that better promote safety in solutions to problems.and construction constraints and therefore require the workplace and aim to reduce the exposure toa solution to these problems without the need to risk. We want to get involved in the end solutionhire more or upskill existing members of staff. rather than just the product itself,” says Tose.Safety is coupled with convenience due to the “This is about using the technology we have to Another concern for AEL in terms of improvingcombination of AEL's technical expertise and improve on safety. There is a big push as an in Africa “is developing the mining industryadherence to legal compliance regulations. industry to make it safe and getting rid of the while conserving 'explosive' part makes it safer,” says Tose. “Here national interest,” says Tose. “It is important toLeading the way in underground bulk systems we have the solution – the missing link – now it is bring local communities on board. There is a“The underground mining method hasn't changed about getting it into the marketplace.” lot of potential in Africa and the nationalin 100 years,” says Tose. “To make inroads in interest is large, but it needs to be balanced.”safety and health, we have fundamentally As an added benefit, UBS technology “is onlychanged our method. The emulsions we have explosive when mixed, so this prevents theft,” Tose provides the new generation Bengalondeveloped for example can now be mixed where says Tose. Pilferage of explosives has been a nitrate plant in Indonesia as an example. “Ourthey are needed, even underground. This challenge for many mines, but the UBS in-line kits are mobile, so we can put plants in.improves security and controls since the 500 people from the areas surrounding the Pilanesberg mine. 7

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Vehicles & Edge ProtectionTransport accounts for a high percentage of accidents in quarries. It has been a priority for ASPASA for manyyears but until the industry addresses safe vehicle, safe workplace, competent driver and supervision it will not improve. None of the things set out below are complicated and there are some basic things that can bedone straight away which will have a significant improvement in the figures. Look closely at you workplace, could this happen to you.Road vehicles – Your haul roads start at the or change your design. 10 degree slop is equivalent uphill on a slight gradient.entrance to the quarry. Can a visitor find their to 17% which is a lot steeper than a 10% slope andway into the quarry and to a point such as car would be too steep for older dump trucks to stop on! Edge protection can be purpose built crash barrierspark or weigh bridge if they are in a lorry Is there or made from suitable materials such as scalpings.sufficient signage. Cars should not be allowed The failure to provide adequate edge protection is Boulders on their own are not suitable as edgepast the car park. Is reversing minimised. Many the cause of many of the vehicle incidents in protection but they can be used to delineate haulloading points are too low for the vehicles that quarries. The recommended height is 1.5m or half roads around flat areas of the quarry.are loaded there. This is not acceptable and the height of the largest wheel using the road or tip,arrangement must be made to ensure that whichever is the greater. As a rule of thumb if you Edge protection should be a minimum of 1.5m (5vehicles can be loaded without reversing. can see over it is probably not high enough. The feet) or the radius of the wheel i.e. half the diameter recommendation is the minimum that is required of the wheel or the axle height whichever is theHave you considered whether the road vehicles and acts as an edge marker to warn the driver of the larger.and site vehicles need to mix. Can the road vehicle. To stop the vehicle going over the edgevehicles be held in a holding bay until they are higher berms are required. These should be The front profile of the edge protection should beneeded at the loading point. Can they be installed in areas where it is likely that a vehicle may made so that vehicles will not drive up and over.separated from the site vehicles. What special go through the edge protection. Remember that edge protection can deteriorate dueprecautions will be taken where they have to to weathering, so it must be properly maintained andcross. Edge protection should be built on a good inspected under the inspection and maintenance foundation. Sand pushed off the edge of the road scheme.Are the road surfaces suitable for road going will be too soft to work and give a false sense ofvehicles. Tipping points for road vehicles shoul security. The purpose of edge protection is to warn the driverbe level. These vehicles particularly articulated that the edge is there. It works by catching thevehicles are prone to overturn if there is a cross Many of the tipping accidents occur when the rear vehicle or by overturning it back onto the road. To dograde, if the tractor unit is not straight with the wheel of the vehicle on the opposite side to the this it has to be well constructed and sufficientlycab (on articulated vehicles) or where sticky driver goes over the edge and the vehicle falls off the large to absorb the momentum of the machine. Partloads are being transported. tip. To prevent this happening the following should of the tip and excavation rules will have to determine always be followed:- the size of the edge protection you intend to use andAlthough site vehicles are big and tough, they where. Guidelines state that it should be 1.5m or thefrequently overturn or are in a collision with one (1) Never reverse towards the tip edge unless radius of the wheel whichever is the larger for mostanother because they are being used in the adequate edge protection is provided. A minimum use. On ramps etc. you may need to put higherwrong conditions. It is essential that basic rules height of edge protection of 1.5m or half the wheel bunds in place.are observed. You should check your site rules diameter whichever is the larger must be provided.to ensure that they can be used safely. Alwayswear your safety belt; it would save 25% of all (2) Some vehicles have their cabs on the left andfatal accidents at quarries. some on the right; others are in the middle of the machine. Therefore always reverse at right anglesRoad widths – Roads need to be wide enough to to the edge protectionallow vehicles to pass with ease, or if they arenarrow one way working or traffic controls will be (3) Never reverse with the wheel diagonallyneeded such as traffic lights. For single track opposite to the driver approaching the edgeroads they should be a minimum of two times protection first. Too many drivers have been killedthe width of the largest vehicle. For two way doing this.roads they should be three and one half timesthe width of the largest vehicle using the road. (4) The edge protection must be provided on theThe dimensions above are the minimum stable part of the tip – edges will fall away as theacceptable widths. ground stabilisesRoad gradients are often misunderstood. For (5) Visibility must be sufficient for the tippingrigid vehicles they should not exceed 1:10. This operation, with all round vision provided to the driveris not the same as 10 degrees. The following and adequate lighting if uses at night. In poordiagrams illustrate this. Brake testing results are visibility such as fog then tipping must bemeasured in % g and can be readily adapted to suspended.the use of % gradient above. For example avehicle with 20% g brake efficiency would not Whether you are driving a road or site vehicle youstop on a slope of 1:5. Thus having designed must only tip on stable ground without a crossyour roads you have to choose a vehicle that is gradient. You should not tip down hill as if the loadsuitable to work within your design parameters gets stuck it will tip the truck over. The best is to tip1010

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ASPASA - overview In instances where natural sand and gravel is unavailable, commercial aggregates are created by crushing large stones or by drilling and blasting rock formations and processing them into various sizes of rock and manufactured sand. This process is called \"quarrying\". Additional processes are required to produce different grades and types of aggregates and sand through drilling and blasting. These crushed stone products can be used for different purposes ranging from creating different grades of concrete, road surfaces or even for drainage purposes and to stabilise land. In the region of 130 quarries are represented by Aspasa.Building our country one stone at a time relationship with the country's training authorities, Adopting change as well as hosting regular workshops and “In addition to this Aspasa supports the adoption ofThe Aggregate and Sand Producers seminars,” Nico says. a proactive strategy to foster change and toAssociation of Southern Africa (ASPASA) is a encourage black economic empowerment andvoluntary producers association that helps to Working together transformation in a sustainable and economicallyimprove the quality of aggregates produced by sensible manner.its member companies for construction projects He explains that quarries represented by Aspasaaround the country. work closely with the Government and the For this reason we subscribes to the aims of the Chamber of Mines and are able to give input on a broad-based black-economic empowermentThe role that Aspasa plays is critical wide spectrum of legislation that affects the charter for the mining industry. In particular, theconsidering that almost every structure made industry, including input on critical issues pillars of transformation related to:by man relies on aggregates for strength and surrounding the environment, as well as health andstability. In fact, construction aggregates are safety matters. · Human resources developmentthe primary ingredients of all concrete · Employment equitystructures and foundations (80% of concrete is These important issues are represented through · Encouraging greater communityaggregate), as well as being the single most expert committees with senior and knowledgeableimportant ingredient used to build our roads specialists serving to give informed input on all participation and development(94% of a road is aggregate). matters. Through these committees programs are · Promoting greater procurement from may also be developed to assist the industry to“Aggregates and sands used in construction meet development objectives and improve the HDSA companiesprojects are naturally occurring minerals that overall standards on member mines. · Encouraging greater HDSA ownershipare mined by a specialised sector of the miningindustry in South Africa mainly from quarries. A specialist technical committee also represents andGovernment strictly regulates sand and the industry on matters that can influence the · Participation and facilitatingaggregate quarries due to the importance of industry. It works with other industry bodies toobtaining a reliable supply of quality materials. ensure that specifications for construction work are beneficiationIt also aims to ensure that the minerals and up to standard and cost effective. Other workmaterials are removed in a manner that is carried out by the association includes assistance “These are not only supported, but we believe willsustainable and protects the rights of workers, with human resources, remuneration surveys, contribute to sustainable development in Southas well as the environment and surrounding workshops on Aids and labour law, employee Africa,” Nico concludes.communities. product assistance (medical aids, pension etc). The association also actively promotes the industry asResponsible association well as the importance of using Aspasa accredited companies.“As a private sector association representingproducers in the industry, we uphold theseaims. In addition we strive to create aneconomically viable industry with goodinteraction between all parties involved, fromthe industry, as well as the relevant governmentdepartments and other stake holders.“Our focus remains largely on creating anenvironment that is fair and equitable, gives ourmembers space to manoeuvre and to make agood living. On the other hand we expectmembers to comply with all relevant legislation,as well uphold the strictest standards in quality,health, safety and environmental issues.Annual audits are in place to assist members toachieve set requirements and also to ensurethat they comply with the relevant legislation“We also encourage skills development and 33nurturing of expertise though our close working1122

Split roller bearings are bearings that have been superior machined brass cage as standard on all their split horizontally through the bore, and can bearings. therefore be removed or installed without OE Bearings are the sole Sub-Saharen agents for SRBhaving to be slid over a shaft end. Split bearings can be Split roller bearings. OE Bearings is unique in thatchanged, or installed without auxiliary equipment they are the only bearing company on the Africanbeing removed from the shaft ends. continent that deal exclusively in split bearings thus making them The only Specialist split BearingTypical positions for split roller bearings are on company.critical equipment, trapped locations between drivesand driven equipment, where access is difficult or The bearing assembly is split to the shaft and can thuswhere sealing or contamination issues affect be changed in an hour or less, as the working loads areconventional bearing arraignments. Typical halved and halved again, so the man power required toapplications for split bearings are fans, conveyor change the bearing is also reduced. Where as a soliddrives, continuous casters in the steel industry, and bearing in a trapped location could take any timemill pinions to name a few, but applications are really between 8 to 24 hours to replace and in specializedlimited to your imagination. cases up to 3 weeks. With down time costs and labourSplit roller bearings are available in three load costs running into hundreds of thousands of Rands.capacity series, namely Light, Medium and Heavy “In such cases, the benefits of using a split bearing areseries. Therefore a bearing can be selected to best suit obvious”the application depending on the load and speed of theapplication. As split roller bearings have machined The sealing arraignment of SRB's is vastly superior tobrass cages they tend to exceed the speed capacities of that of a conventional external bearing, as the splitmost spherical roller bearings. bearing unit has an external misalignment feature so the shaft and seal remain concentric and the sealSplit bearings are not a new concept and have been tolerance is maintained. Of conventional externallyused successfully in industry for over a 100 years. mounted bearings, less than 70% of bearings achieveThis proven concept is available in a variety of their design life, primarily due to lubrication failure asmounting, including Flanges, Take up units, Hangers a result of contamination. Due to SRB's sealingfor screw conveyor center bearings, and Plummer arrangement and the fact that new lubricant is appliedblock type units. With SRB's development of the to the rollers and working surfaces of the bearing, ourSN/SD interchange mounting arraignment with customers are reporting that SRB's exceed thematching bolt holes and center heights to Plummer previous bearing life by more than 60%.blocks, the growth in the split bearing market has beenexponential. So much so, that forward thinking As the quantities are so small, the bearings are almostEngineers are specifying SRB's at design stage due to handmade, they are more expensive than massthe ease and simplicity of replacing components produced solid bearings. This price difference is oftenwhilst still coupled to the drives. The sealing negated by the labour saving, and if downtime andarrangement of split roller bearings is also capable of loss of production is considered, then the cost of thewithstanding the harshest and most aggressive split bearing unit becomes a mute point.environments. OE Bearings not only supply Split bearings but areOver the years many bearing companies have also actively involved from design, to commissioningmanufactured split bearings, but have stopped of bearings sold. To this extent, we identify andproduction as the split bearing market is a niche experience issues our customers face from time tomarket, so it is not viable to make split bearings in a time. Following our onsite experience, OE Bearingsfactory that is set up to mass produce bearings. in conjunction with the Revolvo factory ,developed the SN SD interchange, this allowed for a split bearingSRB bearings are almost handmade, at the Revolvo unit to be fitted in place of a conventional Plummerfactory in England where the product was developed. block without structural modifications having toThe SRB product range has a number of advantages done, as was the case before the birth of SRB.over other split bearings in that all SRB bearings havenotably higher capacities, stronger cast iron and a 13

LOULO-GOUNKOTO SUCCESS DRIVESSUSTAINABLE DELIVERY OF LOCALCOMMUNITY BENEFITSThe Loulo-Gounkoto gold mining projects, which will serve as training during the quarter was the progresscomplex, the largest of its kind in Mali units, have been identified. made with the installation of two newand one of the largest in Africa, medium speed generators, designed tocontinues to make strong headway in its To boost the local economy generally, cater for the complex's growing powerdrive to increase production and contain the complex will fund a microfinance needs while keeping a reign on energycosts, said Randgold Resources' chief provider to help finance small business costs, which are due for commissioningexecutive Mark Bristow. initiatives, particularly those started by in the second half of this year. Power the women in the community. is, by a wide margin, the largestBristow said that the complex's component of any mine's cost structureimportance to the Malian economy was “As the two key stakeholders in this and since 2010 Loulo-Gounkoto hasdemonstrated by the fact that it complex, the government of Mali and been switching to medium speedcurrently accounts for some 8% of the the management of Loulo-Gounkoto generators capable of running on thecountry's GDP. In addition to the have a joint responsibility to ensure that less expensive heavy fuel oil, thussubstantial contribution it makes to the it continues to generate substantial driving down the kilowatt/hour cost ofMalian treasury in the form of benefits for its communities and the its energy consumption.dividends, taxes and royalties, Loulo- country, not just for today but for futureGounkoto's continuing success has also generations,” Bristow said. The next stage is to continue workingenabled it to provide a wide range of with the Malian authorities and otherlife-changing benefits to local “One of the issues we still have to regional governments on the Westcommunities. This, he said, was in line address together is the challenge of African regional power project which, ifwith Randgold's commitment to share illegal mining, which impacts on Loulo- implemented, will not only reducethe value it created with all its Gounkoto's capacity to deliver these Loulo-Gounkoto's energy costs furtherstakeholders, including the people of its benefits and, even worse, is threatening but will unlock many mininghost countries. the integrity of Mali's vitally important opportunities in the region which are national assets, damaging the currently not viable.One of the major achievements of this environment and exploiting sectors ofapproach was the significant the community.” Samba Toure, Randgold GM operationscontribution Randgold was making to for West Africa, said the gratifyingnational skills growth in Mali through In the second quarter to June 2014, the results achieved to date by the Loulo-scholarship programmes, hands-on Loulo-Gounkoto complex again lived Gounkoto team were a tribute to yearstraining and career development. As a up to its status as Randgold's flagship of hard work. “But a winning teamdirect result of this effort, Loulo- operation by posting a 3% increase in such as this always see moreGounkoto is managed and operated by production to 174 052 ounces – its third achievement opportunities, and they'rean almost entirely Malian team, with the successive record breaking quarter. already looking at further performancecountry's nationals accounting for 94% enhancements,” he said.of the total workforce. In addition to a strong operational performance, the Loulo team alsoIn addition, the complex has set up completed the Yalea pastefill plant,community-led commissions to direct which was successfully commissionedeach of its strategic community in July. Commissioning of the Garainvestment sectors, including potable pastefill plant is scheduled forwater provision, education, healthcare September.and food security. Investment projectsare run by the community, with Loulo-Gounkoto general managerguidance from Loulo-Gounkoto's Chiaka Berthe says the significance ofmanagement. this advance is that the paste backfill will enable miners to extract virtuallyAnother initiative is the development of 100% of the high grade zones at Yalealocal agribusinesses. The relevant and Gara. It will also reduce the need tocommunity development committees develop and mine secondary stopes andare being converted into cooperatives, facilitate the optimisation of thewhich during the course of this month ventilation systems. The interim CAFwill be securing agricultural land backfill operation is now being phasedselected by the communities and tested out but served as a useful trainingby Mali's National Agricultural ground for its operators who are beingInstitute. Construction of an transferred to the pastefill plants.agricultural training centre will alsostart this month and a number of pilot Another major milestone achieved14

GRP PIPES - THE RESPONSIBLECHOICE FOR MINING INDUSTRYAPPLICATIONSJOHANNESBURG, OCTOBER 2014 Fiberglass-reinforced plastic is IWC was founded in 1986 and- Labelled the 'pipe of the future', constructed by weaving together specialises in evaporative water coolingcorrosion-resistant, glass-reinforced individual strands of fine glass fibre to for numerous applications. Someplastic (GRP) pipelines can save mining form a flexible fabric, which is then industries in which we are involved are:companies millions on reoccurring placed in a mould and combined withpipeline breakdowns due to corrosion. resin. This process is then repeated in Power GenerationFiberglass-reinforced plastic pipes are order to create many layers of the fibre Miningnow considered exceptionally glass and resin, which then becomes a Petrochemicaladvantageous in the mining industry high performance material of Sugarwhere highly-resilient materials are exceptional strength and versatility. The Steel & Aluminiumrequired to withstand corrosive resin most commonly used in GRP is Food & Beverageschemical used and harsh environmental unsaturated polyesters dissolved inconditions experienced in the mining styrene. Polyesters can be tailor-made to Air-conditioning, Refrigeration andprocess and in particular metals specific industry requirements. many other applicationsprocessing plants. For many years IWC has been a Owing to its strength, durability and member of the CTI, CoolingRoger Rusch, CEO at IWC, experts in non-corrosive properties, GRP pipe Technology Institute, based in the USA.GRP manufacturing and installations in systems have a longer life expectancy This association has as its member'sSouth Africa and Africa, says “GRP when compared to a variety of consultants, designers, constructors aspipes are well-priced, do not require construction materials, making it well as end users of cooling towers.maintenance and are designed to have a massively economical over the long run. With years of expertise and practicallifespan of around 50 years, which is a Furthermore, glass reinforced plastic knowledge, IWC offers bespoke PHEhuge saving on the life cycle cost over a pipes are considerably less expensive maintenance solution at cost-effective50-year period, especially in the mining than those manufactured from materials and competitive pricing.industry where conditions are harsh.” such as stainless steel or more exotic materials that are required in the Due to IWC's extensive experience inIn response to the growing demand for metallurgical processing industry the refurbishment of cooling towers itfibreglass equipment and piping, in Due to its unique physical properties, has undertaken in excess of 80% of the2012, Industrial Water Cooling, IWC, glass-reinforced plastic can be easily Natural Draught refurbishment workofficially launched a glass-reinforced moulded and manufactured to meet conducted in South Africa.plastic (GRP) manufacturing facility in almost any industry specifications. WithIsando, Ekurhuleni, which is one of GRP, there are few constraints on size, IWC has completed the on-lineonly two GRP plants of this kind in shape, colour or finish. refurbishment of a Natural DraughtSouth Africa. Before IWC launched its Cooling Tower in Australia and also inGRP facility, the biggest local supplier South Africa & Zimbabwe.of industrial fibreglass was based inKwaZulu-Natal. Pound for pound, GRP is stronger than steel and sheet metals, has a high“Our facility offers a range of services resistance to environmental extremes,and products including on-site GRP and is resistant to ultra violet light,piping repair work as well as the extreme temperatures, salt air, and amanufacturing and design of corrosion variety of chemicals including mostresistant linings and fittings for pipeline acids.systems.” says Rusch.IWC's GRP manufacturing facility The advantages are of GRP areundertakes the design, manufacture and unmatched and with years of experienceinstallation of GRP piping and fittings and their own plant, IWC consistentlyfrom 25mm up to 2500mm in diameter undertakes custom GRP piping andPolypropylene; PVC and HDPE vessels fitting solutions, from the simplest, toand piping; and GRP corrosion resistant the most challenging applications in thelinings. African mining industry. About IWC Industrial Water Cooling (Pty) Ltd (IWC) are a specialist water cooling company, with specific strength and focus on evaporative cooling systems and cooling towers in particular.

MEDICAL, RESCUE AND MANAGEMENTS SERVICES• Emergency medical and rescue services in remote areas • Occupational health services• Staffing clinics with doctors,nurses and/or paramedics • Ambulance operations• Fire fighters,rescue technicians,rescue boat operators • Ebola isolation camps• Remote site clinic management • Ebola protective equipmentE EQUIPMENT • Medical equipment and consumables • Disaster trailers • Rescue equipment • First aid kits • Ebola PPE • Fire extinguishers • Ambulances and equipmentT TRAINING • First aid training • Disaster management training • Basic fire awareness training • Wilderness first-aid • Fleet driver ssafety training • Paediatric first-aid 33 1616

EZEHUT PRODUCTS 227 Vonkprop street Samcorpark PO BOX 325 Silverton 0127 WHERE POSSIBLE ALL MATERIALS USED ARE SABS MARK BEARINGPanels used by Ezehut consist of high-impact resistant, exterior grade Masonite weatherboard, bolted together with a reinforced galvinised steel work frame. All materials are extremely durable. ECONOMICAL Structures can easily be erected by unskilled labour—all holes are pre-drilled and erection instructions accompany each structure purchased. Also easily dismantled and transported. DURABILITY UNSURPASSED Backed-up by more than 30 years experience in the prefabricated industry. WINDOWS Windows are supplied unglazed. Burglar guards are an optional extra. FLOORS No flooring materials are supplied. Floors can be constructed from concrete, bricks, pavers or any suitable material. * ALL SIZES ARE APPROXIMATE. STRUCTURES CAN ALSO BE MANUFACTURED TO CLIENT’S SPECIFICATIONS. Phone: +27 12 803 7433 Fax: +27 12 803 6211 Sales Consultant: [email protected] E-mail: [email protected] website: www.ezhut.co.za





MM&G Mining and Engineering ServicesMM&G Mining & Engineering Services walked away as the other four category winners, the fabrication of the “The strategy was developed around a definite goal withthe overall winner at the 2012 Steel Awards. The giant complex platforms and flue cans for the world-class handpicked individuals to deliver the project. The fact thatchimney flues and platform steelwork project the company Medupi chimneys truly showed the “wow” factor that the same project team worked on the project fromcompleted at the Medupi Power Station in Lephalale, separates the 2012 SteelAwards winner from the rest. commencement to completion, played a considerable roleLimpopo, also won the Mining and Industrial category in our success. The same key people who designed andprize. The total weight of all the units was approximately 2400 planned the project, also brought it to a successful tonnes, of which the stainless steel component accounted conclusion, and are still with the company today,” saidThe annual Steel Awards, presented simultaneously in for 330 tonnes and the mild steel components, including Vos.Johannesburg, Durban and Cape Town on 6 September, lobster, accounted for 2070 tonnes.serve to recognise and applaud exceptional MM&G did face some safety challenges on the Southachievements within the steel industry and aim to Jurie Human, project director, said there seemed to be a Chimney with two lost time injuries during Novemberrecognise and promote excellence and entrepreneurial perception that MM&G would be unable to complete the 2010. They learned from the mistakes made, and after thatdevelopment in the industry, principally in South Africa, by project within the agreed upon time frame. MM&G maintained an excellent safety record throughoutprofiling innovative thinking and successes from the the project. The fabrication and erection of the flue gasindustry, both locally and internationally. “We proved the nay-sayers wrong. We fabricated our own ducts was completed without fatalities to the workforce, workshop in record time on the Medupi site during January consisting of an average of 80 workers, increasing to aBoksburg based MM&G competed with entries from local and March 2010, and the project started in all earnest in work crew of 107 at peak production times.as well as international individuals and companies May 2010 with the first items of diameter studies, and theinvolved in the production, conversion, distribution, use of first trial assembly done in our Boksburg Workshop,” said MM&G is particularly proud of the fact that the project wasrecommendation of carbon and stainless steel. Human. completed with local content and workforce.MM&G received the order for a fast track project on the All the components for the first three flue gas ducts, for the “There were challenges to overcome, some delays due toMedupi Power Station in December 2009, said CEO South Chimney, were due for completion by 20 March labour strikes and xenophobic unrest, as well as the harshDawie Vos. 2011, a date to which MM&G kept as a result of excellent weather circumstances in which the project had to be planning and execution of the project, said Vos. The completed. Our workforce endured and persevered in“The project entailed the supply and fabrication of flue gas completion date for the second delivery of flue gas ducts, temperatures that had the mercury rising to up to 54°C.ducting for two 220 meter high chimneys, each containing for the North Chimney, had been set for 20 October 2011, Despite these potential stumbling blocks MM&Gthree flues. This was the largest project MM&G had ever and was completed early on 9 September 2011. managed to complete the work within the agreed uponattempted and completed successfully in its 34 year time frame,” said Vos.history. The timely construction and handover of 120 steel The total design of the interior stiffening and fabricationunits, consisting of 18 stainless steel units (316L material), methodology for the flue gas ducts was done by MM&G, MM&G maintained an excellent quality record: The102 mild steel units (S355JR material) and the remainder and was monitored by a computer programme specifically company experienced no quality rejections throughout theof 24 mild steel lobsters (S355JR material) are evidence written and developed for this project in-house. Just in project, and to date there have been no rejections due tothat MM&G can compete with the best,” said a proud Vos. time delivery of value added raw material from the Aveng any defects. This success can be attributed to MM&G's Trident Steel group contributed to the successful delivery 100% ISO compliant Quality system, said Vos.The judges stated that in spite of strong competition from of the entire project.MM&G continually strives to improve its position as a premier steelfabricator and Construction Group Dawie Vos Jurie Human Email: [email protected] Email: [email protected] Specializing in Structural Steel, supplying and servicing the Construction and mining industries. 106, Cnr Bain & West Street PO Box 8908 MM&G are specialists in: Boksburg East Cinda Park Tel: 011-914-4740 Fax: 011-914-4673 1463 Shaft & Station Steelwork and Shuttering Email: [email protected] Gantries & Pipe rack Fabrication Website: www.mmandg.co.za 3 Plate girders design and fabrication Pipe & Tower Structures20 Screw Pile foundation Overland conveyors Structural Steel Fabrication

High Performance Excavation Equipment suction tube is toothed at its end in order to cut filter system and next into the atmosphere. The ground material under excavation is the earth during excavation process. When the deposited to the main storage tank when the operator directs the machine's intake nozzle at excavator is used to suck out debris, the earth the excavation ground and the air flow vacuums the ground material into the vacuum excavator. is first loosened with a compressed air lance or Soil particles are collected in tanks where dust particles are caught in the micro mesh filter a water jet and this type of excavation where a system before the air finally passes from the machine. water jet is applied is referred to as hydro When the ground conditionsExcavators are heavy machines that are used excavation or vacuum excavation. Suction become a challenge, the trained for digging and trenching activities. Excavator excavator is significant in that, it does not operator uses an air lance or equipment has served great purpose in expose the buried utilities in the underground to other air tools, which aremining industries whereby mining activities are done damage while the equipment is used for utility usually connected to theeasily and finding process. vacuum excavator. The ground is loosened through this tool,effectively. In allowing the air flow to catch the material releasing it into theview of the vacuum excavator. The use of vacuum excavator in excavationsuction field as a new approach is not necessarily meant to replaceexcavator, a the traditional or hand dig methods, which are stillproper applicable in excavation process.understandingof excavationequipmentoperating inundergroundcan beachieved. Asuctionexcavator isas well knownas vacuumexcavator,vacuumtanker orvacuum lorry. Vacuum excavator flow chartIt is aconstructionvehicle whosepurpose is to The excavation process by a vacuum excavatorremove debris from the underground through a wide is not complex. The Vacuum Excavatorsuction pipe whose diameter is approximately thirty generates a high volume flow of air by the helpcentimeters. of its triple air fans. The air is then flownSuction excavator in operation through the intake nozzle and hose into aBy the help of suction power, the excavator series of chambers and the main materialoperates at a hundred meters per second. The storage before it is passed through the mesh 21

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ReMaCon offers the YFEL – amodular concrete wall for theseparation of dry bulk mineralsand TW1 - retaining blocks formine tip wall construction.ReMaCon Products have been accommodate changing storage extremely difficult to climb over. Inmanufacturing precast concrete requirements. In mining there is a addition, services such as cabling andretaining blocks since 2005. The YFEL requirement for different grades to be water pipes can be placed through thesystem has recently been launched. It separated. The YFEL system is a spayed void.is an innovative modular product that convenient, flexible and new approachprovides a flexible alternative to the to the traditional methods currently Conduits can be cast into the YFEL toconventional ways of separating stored employed. The YFEL concept has been but cables through to fit lights ordry bulk materials. successfully applied and proven cameras on the YFEL for additional abroad. It will also assist companies security.The YFEL system – with ISO compliance issues in terms ofcheck the website for material separation.the product in action -yfel.co.za/ The YFEL product is manufactured to order in heights ranging from 1,2 m toThe YFEL derives its name from the 4 m. The product can withstandinverted “Y” shape with its abrasive construction machineryresemblance to the famous Eiffel handling due to the 50MPa concreteTower in Paris. It is designed to strength and steel reinforced design.provide easily erectable temporary orpermanent walls as dividers in The YFEL can be bolted into the floorswarehouses and other areas where any of warehouses and other storage areasdry bulk materials are stored and for extra stability. ReMaCon canseparated. supply attachments for moving by forklifts onto and off trucks and forUnlike the traditional permanent positioning on site are available.concrete walls that are built forseparation, the YFEL is easily moved ReMaCon offers the “ANTI-about allowing the freestanding walls CLIMBTM” security feature on the topto be quickly dismantled and moved to of the YFEL unit making the unit 23

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FeatureCONDITION MONITORING LEADERS WearCheck’s reliability solutions managerEXPAND NETWORK IN AFRICA Philip Schutte is dedicated to the optimisation of plant performanceWearCheck - Africa’s leading condition management. ‘To ensure that plant operatesmonitoring company - serves the at peak performance in order to achieveearthmoving, industrial, transport, shipping, maximum efficiency and, ultimately, boostaircraft and electrical industries through the the bottom line, we now offer a range ofscientific analysis of used oil from monitoring techniques, such as the testingmechanical and electrical systems. and control of the efficiency of combustion,Additional services include the analysis of heat transfer and milling,’ he said.fuels, transformer oils, coolants, greases andfilters. WearCheck also offers several other solutions to keep plant performanceThe introduction of a highly capable operating at its peak, including:Reliability Solutions division hastransformed WearCheck into a ‘one-stop The Station Thermal Efficiency Programshop’ for condition monitoring, offering (STEP), Coal Accounting and Plantvibration monitoring, laser alignment, Performance Monitoring Services.thermal imaging and balancing. Plant Performance Monitoring of Boiler,An expansive network includes ten Turbine and Auxiliary Plant.WearCheck laboratories spanning the Routine testing and verification of rawcontinent and beyond, including Gauteng, data from plant used in the STEP systemKwaZulu-Natal, Mpumalanga Province, and or similar programs to produce thermalinternational laboratories in India, Dubai, performance results.Ghana, Mozambique and Zambia - at Investigations and report withLumwana mine and Kitwe - with a presence recommendations on the plant failures orin Cape Town, Rustenburg, Steelpoort, Port incidents.Elizabeth, Zimbabwe and Namibia. Advice on the plant performance tests, including the load lines, clean air curves,Managing director Neil Robinson explains, plant inspections, air flow test, air heater‘The concept of analysing oil samples from leakage tests, O2 verification tests,a machine or component is similar to that of temperature traverse tests, gas velocitytaking a blood sample from a person - the tests, condenser tests, dew point test,results determine the health status of the pulverised fuel sampling tests, generatorunit. WearCheck’s highly-skilled diagnostic H2 leak test, HP & LP heaterteam then analyses the results and performance tests and any otherrecommends how to rectify any abnormal performance and testing tests requiredfindings.’ for the plant optimisation. Assistance with the following duringRobinson is committed to ongoing outages: air heater shoe gaps and sealsinvestment in new technology to ensure that settings, pulverized fuel burner settings,all laboratory equipment is state-of-the-art mills settings, draught plant settings,and rivals, often surpassing, its local and zeroing of coal conveyor mass metersinternational counterparts. All laboratories and any other settings that may beare largely automated and integrated with required during the plant outages.the latest information technology. Researchand development plays a major part inWearCheck’s commitment to continualimprov em en t. 25

· Weekly plant walk-downs and liaison Captions: with the operating department for any deviations that are visible on the plant 1. Condition monitoring specialists for corrective action to be taken. The WearCheck process in excess of activities are performed on the whole 600 000 oil analysis samples each station, including turbine, boiler, mills year in ten laboratories. Here, and outside plant. despatch clerk Michelle Alexander sorts oil samples.Backed by certification from Paris-basedBureau Veritas and Honeywell, WearCheck 2. The most recently-openedis the only oil analysis company in Africa WearCheck laboratory is in Tete,with ISO 9001 quality certification and ISO Mozambique – their first in East14001 certification for its environmental Africa. Equipped with the latestmanagement programme, and ISO 17025 high-tech instruments, the lab offersaccreditation for its laboratory-centric fast sample turnaround time andquality management programme. highly accurate oil analysis results.WearCheck has been awarded preferredsupplier status by several Original 3. WearCheck’s managing director,Equipment Manufacturers (OEMs); notably Neil Robinson, believes that aBell,Liebherr, Volvo Construction combination of ongoing investmentEquipment and,along with WearCheck’s in the latest technology, unwaveringglobal partners, is the laboratory of choice service excellence and a strong focusfor a number of lubricantsuppliers. on ethical management, ensures thatWearCheck also has a partnership with ABB his company remains at the helm ofLimited, Zurich - a global leader in power the proactive condition monitoringand automation technologies. These industry.partnerships are in line with worldwidetrends in outsourcing specialist services. 4. WearCheck’s reliability solutions manager Philip Schutte and his teamWearCheck’s operational areas are managed focus on optimising plantethically and independently to ensure performance management. Theyproducts and services conducted comply have developed a comprehensivewith the company’s strict international suite of tests to monitor potentialstandards. problems using techniques such as vibration monitoring, thermalWEARCHECK’S CONTACT DETAILS: imaging and laser alignment.Email: [email protected]: www.wearcheck.co.za Released on behalf of WearCheck byTel: Durban (South Africa) (head office) Sharon Fay Public RelationsTel: +27 (0) 31 700 5460 Media queries:Sharon 082 8230539 or [email protected]

Kipoi Mine in DRCKipoi mine is a joint venture located in consistently above the nameplate capacity. the province of Katanga in DRC It is in the same year that the company whose main mining product is managed to increase the copper stockpilescopper. Kipoi mine in DRC is a project to 4.7 million tons, which were planned to beowned by Tiger Resources, used as feed to stage two plant known asGé camines company. Just like any other solvent-extraction electro winning (SX-EW)project of a given company, Kipoi mine in in the recently passed year 2014 andDRC has had challenges and achievements hopefully in the current year 2015.through goals and plans set upon it. Theseare occurrences that have taken place in the On the other hand, government policy wasrecent years bearing in mind that Kipoi mine speculated to be a limitation to the Kipoiin DRC is a project whose production mine project, when the DRC governmentobjectives were set to be fulfilled in the last decision pronounced banning of copper andfew years. For instance, a target had been cobalt exports. In addition, the countryset that the mine should reach a capacity of pressed that the companies should process100, 000 tons of copper metal per year and and refine the metals within the country'sby the year 2011; the mine had managed to borders. On the contrary, there was a greatproduce at least capacity of 130,000 metric domestic demand for the Tiger's producttons. which was especially marked by smeltersKipoi mine project enabled its respective within DRC. Thus, this turned out to be ancompany to make a record of quarterly advantage to the Kipoi mine project as moreproduction in DRC. The Tiger company than eighty percent concentrate of itsproduced over twelve thousands tons of product was sold to the smelters within thecopper from its heavy media separation same period. Also in support of the sameplant in the September quarter, which was government, the remnants of the Kipoi minean indication that in percentage of thirty five, project products were exported to Zambia.it was higher than the plant's nameplatecapacity as well as than the previous In conclusion, it is clear that the Kipoi minequarterly production record with percentage project in DRC has gone through phasesof nine. As a result, the project became good especially in the year 2013, which haveenough to be recognized as a world class reflected a promising future for Tigerproject with an outstanding team of the Company. Needless to mention that thecompany. In the year 2013, Kipoi Mine DRC government and the heavy mediaCompany in DRC could produce above thirty separation operations have as welltwo thousand tons of copper in concentrate supported Tiger's company operations,which was an achievement that gave great which will enable the company to produceimpression that it has ability to operate high-value added copper cathode products. 27





ASSA ABLOY Entrance Systems, the world’s mostcomprehensive supplier of entrance automation solutions,proudly introduces the Albany RR1000, a tough, high-speedrubber door refined with a sophisticated new design.This attractive yet manufacturing facility or a rugged high- mining operation set in harsh performance door environmental conditions, thepacks strength and power into Albany RR1000 is suited toa low-clearance header with a operate exceptionally and looksleek finish, thin low-profile good.side frames and a versatilerubber door curtain available When fast-paced operationsin a range of colors. are busy, accidents are inevitable. The AlbanyIndependent wind- RR1000 will break awayperformance tests have shown easily, and can be reset simplythat the Albany RR1000 can and quickly with the push of asafeguard people and goods, button. This self-repairing,resistant up against strong break-away function roundsgusts of wind and extreme out a full host of features,weather conditions in exterior including impressively highapplications, and withstanding opening-speeds of up to 60”air pressure in interior per second and superior safetyapplications. Even hurricane- systems to protect people andlevel winds should not derail equipment.the Albany RR1000, whichcan tolerate 130mph “We’re proud to offer thiswindloads. innovative product that will change the face of the high-The rubber door panel is speed door industry,” saysdesigned to remain firmly in Juan Vargues, President andthe side-frame guides without CEO of ASSA ABLOYlifting upwards, a common Entrance Systems. “With theproblem when traditional high wind resistance and thebottom seals meet intense refined design, the Albanywind and air pressure. This RR1000 is unprecedented instrength and reliability is today’s market.”backed by a lifetime warrantyon our thick, high tensile For more productstrength rubber door panel. information regarding Albany mining and industrial doors,This resilient performance is please contact:matched with an aesthetically Maxiflex Doors Systems,appealing design, making the info@maxiflex.co.za,Albany RR1000 an excellent +27 11 3921709choice for buildings aiming forarchitectural elegance andstyle. Be it a parking garageon a state-of-the-art officebuilding, a busy30

RKA CONSULTING We are the Leading Supplier of Technical Support , Training andPILNESBERG PLATINUM PROJECT Product Sales of GE-IP Software in South Africa . Platinum Mines Ltd Specializing in IFIX , FIX32 , FIX DMACS , Proficy Historian , Proficy Portal from GE Intelligent Platforms ( Ex GE Fanuc , Ex Intellution )Postal AddressPO Box 12130Vorna Valley1686South AfricaTo contact us:Phone: 083 456 4165 or 011 8055744Fax: 0865030094E-mail: [email protected] Consulting ccMidrandSouth AfricaRKA Consulting cc 4 31