Tag Archives: Africa

Metso HIGmill heading to African copper project

Base metals, Comminution of minerals, Mining equipment, , , , ,

Metso says it has been awarded an order to deliver grinding mills to an African copper mining project, with the order representing approximately €20 million ($22 million) of business.

Metso’s scope of delivery consists of energy-efficient HIGmill™ high-intensity stirred mills with auxiliary equipment and services, it says.

The OEM has experience with over 8,000 grinding mill installations globally, including manufacturing and delivering the largest SAG/AG and ball mills in the world, it says.

Metso’s HIGmill is an advanced and energy-efficient fine and ultra-fine grinding solution and is part of its portfolio of stirred mills that meets a wide range of customer requirements. The HIGmill takes advantage of gravitational forces and GrindForce™ rotor technology to produce a finer grind for mineral liberation. It is also part of Metso’s Planet Positive offering.

Murray & Roberts Cementation - Mock up

Murray & Roberts Cementation presents ‘mock-up’ facility for underground mechanised mining

Careers in mining, Mining services, , , , ,

Through its new mechanised mining ‘mock-up’ facility, Murray & Roberts Cementation says it is giving equipment operators and supervisors a more realistic learning experience. This enhances safety and is more cost effective than doing this level of training on a working mine, argues Education, Training and Development Executive, Tony Pretorius.

Known for its extensive mine training offering and innovative learning approaches, Murray & Roberts Cementation says it has further raised the bar with this facility for underground mechanised mining.

Pretorius says the new installation is a quantum leap for mining-related training in Africa. Located at the Murray & Roberts Training Academy (MRTA) at the company’s Bentley Park complex near Carletonville in Gauteng, South Africa, the new facility will give a fully immersive learning experience across the underground mining value chain.

“Our new mock-up facility is as close to a real mine as you can get,” Pretorius says. “Learners experience not only the look and feel of an underground bord-and-pillar mine, but even have the smells and sounds of such an operation.”

He emphasises that this experience is a valuable next step to complement the simulated and virtual reality platforms already provided to learners at the MRTA facility. To build skills, operators need to put their theoretical learning into practice – but the pressurised production environment of a real mine is often not the ideal location.

“Rather, our new facility provides a safe and low-cost learning environment, where learners can practice their skills without hindering production or compromising safety,” Pretorius says. “At the same time, they still get the sensory experience for developing the muscle memory they require for the real-life workplace.”

Equipped with essential first-line equipment such as drill rigs and bolters, the facility also has its own machinery for loading, hauling and dumping blasted rock. The realistic environment includes ventilation systems, support structures and blasting systems.

“Learners are taken through the full value chain of mechanised mining activities, from the waiting places, entry exam and safe declaration to the installation of support and cleaning of blasted rock,” Pretorius says. “They conduct marking, drilling and indexing of the face wall, charging up with inert explosives and simulating the blast with a centralised blasting system.”

He explains that MRTA’s extended reality framework follows the situational leadership model, which places considerable value on learner participation in activities – to entrench their applied competence. Built over recent years, the facility is housed in a large covered structure 3.5-m high and covering some 1,125 sq.m. Together with its dedicated equipment, it represents an investment of over R35 million ($1.8 million), he says.

Delta Drone and Strayos team up to improve mine site decision making

Automation, IoT, Mine surveying, Mining equipment, Mining services, Mining software, , , , , , , , , ,

Drone-based data provider, Delta Drone International Limited, has announced a new product addition to its data solutions business model via its partnership and distribution agreement with AirZaar Inc, a corporation doing business as US-based, mining-focused software provider Strayos.

The arrangement will allow DLT to distribute software licences across Africa and Australia, either directly or via resellers and consultants. DLT will apply the solution in an integrated way
for existing and new customers to process and value-add drone captured data. In addition, customers will gain extra value from the Strayos platform more broadly, given its multi functionality to generate ongoing operational insights across business operations.

DLT CEO, Christopher Clark, said: “We have been assessing the markets in which we predominantly operate, being Australia and Africa, and have identified that our customers want a stronger vertically integrated solution that not only includes data capture but also data insights. Overlaying AI-intelligence in our current data workflows adds a higher value proposition to the end user, resulting in faster turnaround of reporting and ultimately simplifying decision making within these complex environments.”

Clark said the partnership with Strayos was mutually beneficial, with Delta Drone International seeing an increased revenue mix of software sales while Strayos would leverage the drone-focused provider’s global presence and geospatial experience “to ensure customers receive seamless on-boarding and continuous support”.

Strayos, Delta Drone says, has developed a unique software platform with advanced image processing, digitalisation and artificial intelligence tools designed to improve safety, efficiency and productivity in mining job sites.

DLT added: “Strayos’ software is primarily data-enabled by aerial imagery and LiDAR, captured by drones, and used to create digital twins of sites. The digital twins can be further enhanced by adding data from additional sensors from mining equipment. Strayos AI generates insights that help mining management and engineers make faster more informed decisions and ensure conformance across their operations.”

Strayos CEO, Ravi Sahu, said: “By partnering with Delta Drone, customers in Africa and Australia will be able to take advantage of Strayos’ AI powered solutions and insights to optimise their operations for safety, sustainability and productivity from mine to mill. Delta Drone is an excellent partner for this market expansion as they can immediately expand the products and value add they offer to their current customers and are well-positioned to support new customers.

“Working with Delta Drone is the beginning of an exciting new chapter in making advanced AI solutions easily available to the mining industry.”

Platinum producer targets improved filter life with Metso Outotec preventative maintenance contract

Environmental, Equipment maintenance, Mining equipment, Mining services, Precious metals, Sustainable mining, Water management, , , , , , , , ,

Metso Outotec says it has signed a three-year Life Cycle Services (LCS) contract with one of the biggest platinum producers in the world, aiming to provide a preventative maintenance solution that will improve machine life.

With LCS, the customer’s critical assets will achieve enhanced availability and higher production, according to Metso Outotec, adding that the performance-based agreement provides, among all, a Reliability Centered Maintenance application that focuses on preventive maintenance.

The value of the order is approximately €16 million ($15.9 million) and it covers 12 filters across five customer sites.

Vivian Pillay, Director, Global Key Account Management in Metso Outotec, said: “We are very pleased to have been chosen as the key supplier of filter services for our customer’s sites. Our service approach will improve the safety, overall filter reliability and performance in line with customer’s throughput targets.”

Metso Outotec’s LCS offering covers the entire after-market portfolio, including process support and optimisation, sustainable wears, spares, and service solutions. Core service elements in the LCS packages for filters are spare parts, repairs, maintenance, reliability, connected equipment and process optimization.

The company says it has the most comprehensive filtration portfolio on the market with 15 different filter types available for hundreds of applications. It has performed over 14,000 filtration tests and has delivered over 5,000 filters around the world.

Metso Outotec to supply electrowinning equipment to copper cathode plant in Africa

Base metals, Mining equipment, , , ,

Metso Outotec says it has been awarded a contract for the delivery of advanced electrowinning equipment to a copper cathode production plant in Africa.

The order value amounting to approximately €11 million ($11.5 million) is booked in the company’s Minerals Q2/2022 orders received.

Metso Outotec’s scope of delivery includes the supply of basic engineering and equipment for the copper electrowinning plant expansion, it said.

The OEM’s offering for copper electrowinning tankhouses comprises pre-engineered solutions, key equipment and services to ensure superior process performance, increased safety and minimised environmental impact.

Metso Outotec to deliver first integrated beneficiation and pelletising plant

Comminution of minerals, Environmental, Mineral processing, Mining equipment, Mining services, Steel and iron ore, , , , ,

Metso Outotec says it has signed a landmark contract for the delivery of an iron ore beneficiation and travelling grate pelletising plant to Africa.

While the parties have agreed to not disclose the value of the contract, the scope of delivery includes the engineering and supply of key process equipment for the beneficiation and pelletising plant.

In addition, Metso Outotec will provide site supervision and commissioning services and deliver automation and training for the project, which the OEM conducted early engineering works for in 2020.

“This new greenfield plant is the first integrated beneficiation and pelletising plant we are delivering globally,” Jari Ålgars, President, Metals business area, said. “It will feature Metso Outotec’s sustainable proprietary technology, such as Low NOx burners to minimise emissions in the process, as well as state-of-the-art digital solutions, including our Optimus™ process optimiser and a green pellet-size control system.”

Optimising energy management at B2Gold’s Fekola mine

Environmental, Mine operation news, Mining services, Power supply for mines, Precious metals, Sustainable mining, , , , , , , , , ,

The delivery of a cutting-edge 17 MW/15 MWh energy storage platform and Wärtsilä’s advanced GEMS system is optimising energy management at B2Gold’s Fekola gold in Mali, Luke Witmer* writes.

Since B2Gold first acquired the Fekola gold mine, located in a remote corner of southwest Mali, exploration studies revealed the deposits to be almost double the initial estimates.

A recent site expansion has just been completed, and while the existing power units provide enough power to support the increase in production, the company sought to reduce its energy costs, cut greenhouse gas emissions, and increase power reliability.

The addition of a 35 MWp solar photovoltaic (PV) plant and 17 MW/15 MWh of energy storage to the existing 64 MW thermal engine plant was decided. This new energy mix is anticipated to save over 13 million litres of fuel, reduce carbon emissions by 39,000 t/y, and generate a payback in just over four years.

Such an elaborate hybrid configuration needs a powerful brain to deliver on all its potential: Wärtsilä’s GEMS, an advanced energy management system, has been set up to control the energy across the fleet of power sources, thermal, renewable, and battery storage. The integration, control, and optimisation capabilities provided by GEMS allow the thermal units to be run at the most efficient rate and enable the battery storage to handle the large load step changes and volatility of the solar PV generation assets.

Integrated hybrid energy solution

In the context of the Fekola mine, which is an off-grid electrical island, the battery is performing a lot of different services simultaneously, including frequency response, voltage support, shifting solar energy, and providing spinning reserves. The energy load is very flat, with a steady consumption rate around 40 MW as the mining equipment is operating consistently, 24/7. However, if an engine trips offline and fails, the battery serves as an emergency backstop. The controls reserve enough battery energy capacity to fill the power gap for the time it takes to get another engine started, and the software inside each inverter enables the battery to respond instantaneously to any frequency deviation.

The reciprocating engines operate most efficiently at 85-90% of their capacity: this is their ‘sweet spot’. But if there is a sudden spike in demand, if a little more power is needed, or if mining equipment is coming online, then another engine needs to be run to meet the extra load.

With the battery providing spinning reserves, the engines can be kept running at their sweet spot, reducing the overall cost per kilowatt hour. Moreover, with the solar plant providing power during the day, three to four engines can be shut down over this period, providing a quiet time to carry out preventive maintenance. This really helps the maintenance cycle, ensuring that the engines operate in a more efficient manner.

Solar PV volatility can be intense. On a bright day with puffy clouds passing by, a solar farm of this size can easily see ramps of 25 MW over a couple of minutes. This requires intelligent controls, dynamically checking the amount of solar that can be let into the grid without causing an issue for the engine loadings or without overloading the battery.

Conducting the orchestra

The GEMS intelligent software provides the optimisation layer that controls all the power sources to ensure that they work together in harmony. The user interface (UI) gives access to all the data and presents it in a user-friendly way. Accessible remotely, all operations are simulated on a digital twin in the cloud to verify the system controls and simulate the most efficient operating scenarios to lower the cost of energy.

This is an important software feature, both during and after commissioning as it allows operators to train on the platform ahead of time and familiarise themselves with the automated controls and dynamic curtailment of renewables. The UI provides the forecast for renewables and the battery charge status at any given moment, it can provide push email or phone notifications for alerts; telling operators when to turn off an engine and when to turn it back on.

The software is constantly analysing the data and running the math to solve the economic dispatch requirements and unit commitment constraints to ensure grid reliability and high engine efficiency. Load forecasting integrates the different trends and patterns that are detectable in historic data as well as satellite based solar forecasting to provide a holistic approach to dispatching power. The Fekola site has a sky imager, or cloud tracking camera with a fisheye lens, that provides solar forecasts for the next half hour in high temporal resolution.

To ensure that operators really understand the platform, and have visibility over the advanced controls, the UI provides probability distributions of the solar forecast. Tracking the forecast errors enables operators to see whether the solar is overproducing or underproducing what the forecast was expecting at the time and provides visibility to the operators on the key performance indicators. This feedback is an important part of the machine/human interface and provides operators with insight if an engine is required to be turned on at short notice.

Automated curtailment enables the optimisation of the system providing a reactivity that people cannot match. By continually monitoring the engine loadings and battery, the system is ready to clamp down on solar if it gets too volatile or exceeds some spinning reserve requirement. For example, if a large, unexpected cloud arrives, the battery is dispatched to fill the gap while the engines ramp up. Once the cloud disappears, however, the engines remain committed to operating for a few hours, and the solar power is transferred to recharge the battery.

Over time, as load patterns shift, the load forecasting algorithm will also be dynamically updating to match the changing realities of the load. As mining equipment hits layers of harder rock, increasing the power load, the system will adjust and dispatch the engines accordingly.

The new gold standard

The Fekola mine project incorporates the largest off-grid hybrid power solution in the world, demonstrating the growing case for clean energy and its sustainable and economic potential for mines in Africa and beyond.

As the cost of batteries and solar panels continues to become more competitive, hybrid solutions are proving to be a realistic and effective means for increasing energy reliability and lowering operating costs in any context, thus freeing up resources to improve the human condition; whether through cheaper materials and gainful employment, or by providing broader access to reliable electricity for healthcare, education, and improved quality of life.

*This piece was written by Luke Witmer, General Manager, Data Science, Wärtsilä Energy Storage and Optimization

Astec Industries looks to boost Africa and Middle East business with Aramine tie-up

Bulk handling, Comminution of minerals, Mining equipment, Mining services, , , , , , , , , , , , , , , , , , ,

Astec Industries, through its newly organised Africa and Middle East (AME) business unit, has announced a distribution partnership with France-based mining and underground solutions specialist Aramine.

This strategic alliance will enhance the supply, distribution and service of Astec mining, quarrying and materials handling equipment in numerous African countries, Astec said. This includes rock breaker systems, rock crushers, feeders, vibrating screens, conveyors, washing and classifying equipment for open-pit mines, alongside underground mining products and bulk material handling systems.

Aramine has been appointed as a dealer for Astec Material Solutions products in Mauritania, Mali, Senegal, Guinea, Ivory Coast, Burkina Faso, Benin, Togo, and Niger in West Africa, as well as in Algeria, Tunisia and Morocco in the Maghreb region.

Vinesh Surajlall, Director – Material Solutions at Astec AME (pictured), said: “The expansion of the Astec portfolio that will be distributed by Aramine is an important evolution in our commercial relations, as we collaborate in very active and demanding markets in West Africa and the Maghreb.

“With this partnership, we are developing a new customer proximity offer, combining expertise, services and quality products.”

Jaime Martel, Key Regional and Product Manager and Head of Distribution Partnerships at Aramine, says the new venture represents Astec’s confidence in Aramine. The two organisations have enjoyed a longstanding distribution partnership which previously encompassed only the BTI range of rock breaker and boom systems.

“The extension of our alliance, to cover the material solutions offering, will equip us further in meeting the needs of our customers in the regions,” he noted.

In addition to its recognised expertise and technical service, Aramine will leverage its networks of subsidiaries and partners in the regions, Astec said.

The recent group restructuring and the establishment of Astec Industries AME will deliver further benefits for Astec customers in the region, the company says.

“The move forms part of Astec Industries’ international expansion strategy, with regional sales organisations established to improve customer interaction and support for the complete range of Astec products,” Astec said. “Astec Industries AME is one of these regional sales organisations and will be responsible for business relationships in Africa, the Middle East and Central Asia. The AME offices are based in Elandsfontein, Johannesburg, with regional sales managers positioned strategically within the region to support the business’s dealer network and customers.”

Surajlall concluded: “We look forward to contributing to the continued growth of our customers’ businesses through this enhanced structure, optimised product range and support structures throughout the Astec Industries organisations. This expanded partnership with Aramine represents an important opportunity to strengthen the presence of Astec Industries Inc in these significant territories.”

Symboticware partners with Ramjack Technology Solutions to expand global reach

Automation, IoT, Mining equipment, Mining services, Mining software, , , , , , , ,

Symboticware’s vehicle sensor data telemetry and analytics solutions is likely to receive a bigger global audience after the IoT specialist signed a reseller agreement with Ramjack Technology Solutions.

Ramjack will be a Value Added Reseller in Africa, Europe, the Middle East and parts of Latin America, according to the company. Ramjack is a specialised, systems integrator dedicated to operations technology for the mining industry.

Symboticware, meanwhile, focuses on standardised information-based technology to enhance productivity, sustainability, profitability and safety through real-time data management solutions.

“Through partnerships with best-of-breed, global technology manufacturers and custom-designed service offerings, they provide mining customers with technology solutions that guarantee improvements in safety, productivity and effectiveness,” Symboticware said of Ramjack.

“Using a pragmatic combination of advanced technology products and services – purpose-built for the harsh mining environment – Ramjack bridges the critical gap between original technology manufacturers and mine operations, enabling mines to realise the full potential their technology promised.”

Kirk Petroski, President & CEO Symboticware Inc, said partnering with Ramjack as a value added reseller extends the company’s global reach, and delivers capabilities for advancements in industrial IoT and artificial intelligence into mining corridors “where a significant positive impact on mobile asset safety, visibility and efficiency can be realised”.

Mike Jackson, President & CEO of Ramjack Technology Solutions, said: “We’re very excited about our partnership with Symboticware. Mines in the regions that Ramjack serves are poised and ready to take real advantage of Symboticware’s vehicle sensor data telemetry and analytics solutions. We are looking forward to the opportunity to demonstrate the rapid returns that this technology can offer to both open-pit and underground mines.”

Weba’s custom-designed chutes find favour in Africa

Bulk handling, Equipment maintenance, Mineral processing, Mining equipment, Mining maintenance, Mining services, , , , , , , ,

Weba Chute Systems’ Wade Vandenberg says mines across Africa are recognising the value of the company’s custom-designed chutes in controlling material flow, extending wear life and reducing maintenance downtime.

The South Africa-based company’s transfer point solutions have made their way into mines across Africa, from platinum to diamond operations, to gold, coal and copper mines.

In addition to mining hotspots including Ghana, Mali, the Democratic Republic of the Congo, Zambia, Zimbabwe and Botswana, Weba Chute Systems have been installed in countries like Tanzania, Mauritania and Eritrea, it says. Authorised Weba Chute Systems agents are deployed to support customers in key countries, while technical experts from the company’s head office in Germiston, Gauteng, South Africa, are on call to assist.

Vandenberg, Weba Chute Systems’ Technical Advisor, Africa, said: “Not only do these operations gain the benefits of controlled material flow in their operations, but they experience, first-hand, how our engineering design extends wear life and reduces maintenance downtime.”

He highlighted that better dust control – a key part of health and safety policies in the mining sector – is another important benefit Weba chutes bring to an operation.

“Our state-of-the-art digital engineering design facilities and expertise makes use of the latest technologies to simulate the specific material flow conditions in each customer’s application,” Vandenberg said. “This allows us to apply our philosophy that no two chute designs are identical, and to scientifically accommodate exact flow characteristics into our design.”

Discrete element modelling allows close control over the flow of material through the chute. This minimises turbulence, reducing the levels of dust created in the working area. It also cuts spillage levels, which, in turn, means a saving of valuable material and less time spent on cleaning activities.

Izak Potgieter, Systems Manager at Weba Chute Systems, said: “We work towards the ISO dust management standards, supporting our customers in managing health and safety in this critical area of transfer points. Our testing measures dust down to 0.03 micron particles, to make sure that our designs meet stringent health-related targets.”

Flow control also creates more material-on-material movement to reduce wear on chute liners, according to Weba. This ensures longer liner life when compared with that of conventional chutes. Custom design and use of simulation technology allow for the wear life to be carefully predicted, based on operating conditions, the company says.

Vandenberg said: “Our technical expertise and solutions-oriented approach mean that customers can always rely on us. When we commission one of our chutes, it is part of an ongoing productivity journey with our customer, no matter where they are located.”